MPU11/GPIO4D Mach3 Mill Kit
Installation Manual
Last revised 2010-08-17 (277)
Table of Contents
1. Introduction
2. What's included
3. Order Of Installation
4. Desk/Benchtop connection, software and network installation and configuration
5. Mounting major components in electrical cabinet
6. Connecting and testing major components in the electrical cabinet
7. Wiring basic sub-systems
8. Configuring motors, encoders and limit switches in software
9. Wiring auxiliary sub-systems
9.1 Lube pump
9.2 Coolant pump
9.3 Spindle
2. What's included:
Make sure your kit is complete and has not been visibly damaged in shipment. The basic
GPIO4D kit includes:
The Ajax CNC11 Based CNC Kit you purchased contains: Qty
1. GPIO4D 4 axis 3rd party Servo Drive interface with integrated PLC 1 ea.
2. MPU11 Motion Controller 1 ea.
3. Fiber Optic Cable 2 ea.
4. +-12VDC, 5VDC Digital Power Supply 2 ea.
5. 110VAC power cable for digital PS 2 ea.
6. Power Cable - Digital PS to MPU11, GPIO4D 2 ea.
7. – 11. Connectors & Misc
8. Software Install & Documentation CD
FIG.2
3. Order Of Installation
Section 4 - Desktop/Bench top connection -
4.1 Connecting the major components
4.2 Power up for the first time
4.3 Software installation and configuration in Windows XP
4.4 Testing PC, MPU11 and PLC communications
4.5 Testing PLC I/O and Analog outputs to drives
Section 5 - Mounting, connecting major components in your electrical cabinet
Mount, connect and test PC, MPU11 and GPIO4D
Section 6 - Wiring Basic Sub-systems
6.1 Wiring limit switches and Estop PLC Input
6.2 Testing limit switches and Estop input
6.3 Wiring encoders
Section 7 - Wiring 3rd Party Servo Amplifiers to the GPIO4D
7.1 Wiring enables
7.2 Wiring GPIO4D External Drive Fault Input
7.3 Wiring GPIO4D Analog Control Voltage
Section 8 - Configuring motors, encoders and limit switches in software
8.1 Configuring motors to move in the correct direction
8.2 Configuring motors to move the correct distance
8.3 Configuring your limit switches
8.4 Configuring backlash compensation
Section 9 - Wiring Auxiliary Sub-systems
9.1 Lube pump
9.2 Coolant pump
9.3 Spindle
9.3.1 Reversing Contactors
9.3.2 VFD/Inverter Wiring – AutomationDirect GS2
4. Desk/Bench Top Connection & Software Install.
4.1 Connecting the major components The first step in the installation is to connect the major
components together on your desktop as depicted in Fig. 3 below. Be sure that your surface is
non-conductive and that you use a power strip so that all you components are powered on and off
at the same time. When everything is connected, your setup should look similar to the photo in
Fig. 4 on the following page. At this point, the only connections that should be made are:
a) The 110VAC from the power strip to the digital power supplies.
b) Connect the digital power cables to the MPU11 and GPIO4D
c) CAT5 network cable from the PC to the MPU11
d) Fiber optic cables (2) from the GPIO4D to the MPU11
c
4. Desk/Bench Top Connection & Software Install. (cont)
4.2 Powering up for the first time With the major components all connected, confirm that all
components are resting on a non-conductive surface and turn on your power strip to power up your
components and PC. While powering up, you notice that there are 4 LED's next to the power
connector (see yellow rectangle below) on the MPU11 that flicker while the MPU11 is initializing.
After 15-30 seconds the LED's should be in the following states:
FPGA-OK = Solid green
DSP Debug = Flashing ~1 per sec
DSP -OK = Solid Green
+5V = Solid Green
FIG.4
4. Desk/Bench Top Connection & Software Install. (cont)
4.3 Software Installation and configuration on Windows XP With your desktop
configuration completely powered up as described in section 4.2. Install the Mach3
Software and configure Windows to communicate with the MPU11 hardware
4.3.1 Installing Mach3 Software Install mach to the default location
Select the Mach3 packages – do not install the parallel port drivers
4. Desk/Bench Top Connection & Software Install. (cont)
4.3.1 Installing Mach3 Software (cont)
No custom profile is needed, the Ajax plug-in will create it's own
4.3.2 Obtaining and installing the latest Ajax Mach3 plugin version
The installation program, setup-mach-ajax-v#.##.exe for the Ajax Mach3 plug-in can be
found in the root directory on the DVD supplied with all Ajax MPU11 systems is also
available for download* from the AjaxCNC website at:
http://ajaxcnc.com/tech/downloads/software/. It is recommended that you check to make
sure that you have the latest version of the plug-in before installation.
If you are running from the DVD, double click “setup-mach-ajax-v#.##.exe ” to begin the
software installation. If you downloaded the software from the website, extract the files to a
local directory and then run “setup-mach-ajax-v#.##.exe”.
When the installer begins, you will be presented with a list of checkboxes to select which
package – Mill, Lathe, Mill Demo or Lathe Demo. Select only “Mill” and click “next”. When
prompted for the installation drive, leave it at the default location (c:\), click “next”. When the
CNC11 installation is complete, click “Next” and then “Finish”.
*Requires username and password to access link. If you do not know your username and password, please
email tech@ajaxcnc.com to request it. When emailing, be sure to provide the customer name and address
that your MPU11 system was purchased under or your system serial number. We cannot process your request
without this information.
4. Desk/Bench Top Connection & Software Install. (cont)
4.3.2 Obtaining and installing the latest Ajax Mach3 plugin version (cont)
Select the brains to be installed. Select the default brains and, if you have a jog
pendant, install the pendant Brains as well, don't select mpg, 4th axis etc... we will
install those later
Configure your network adapter Make sure you allow the installer to set the IP address
(10.168.41.1) of the adapter in your PC or it won't be able to see the MPU11. NOTE: If you have
more than 1 network adaptor installed - select the adaptor with the IP adddress that begins with
169.xxx.xxx.xxx as shown below
4. Desk/Bench Top Connection & Software Install. (cont)
4.4 Starting Mach for the first time
Before running Mach3 software for the first time, you must first configure Windows firewall to
allow Mach3 access to the network to communicate with the MPU11 hardware.
4.4.1 Configure Windows Firewall To Allow Mach3 to Communicate With The MPU11.
Double click the CNC11 Mill icon on your desktop to start the CNC11 software. Depending
on your XP Windows Firewall configuration, you may see the window below when you first
try to run Mach3. You must click “Unblock” to allow Mach3 to communicate with your
MPU11 and for Mach3 to operate correctly.
Once Mach3 has started and initialized the MPU11, you should see "Ajax Hardware
detected" in the bottom left of the Mach screen.
Congratulations! You have successfully configured your PC and Mach3 to
communicate with the MPU11 motion controller.
4. Desk/Bench Top Connection & Software Install. (cont)
4.4.2 Configuring the Ajax Mach3 plug-in Select Config from the top menu in Mach, when
the plug-in pop-up windows comes up, select the yellow CONFIG box next to Ajax Plugin:
This brings up the Ajax Plugin configuration screen. Changing the value in "Stop on Encoder
Error" from 1 to 0 will prevent a fault from being generated while we test without the
encoders connected, leave the "Message on Encoder Error" value set to 1. This will issue a
warning message on the screen to remind us that the encoders are not connected but it
won't trigger any faults:
4. Desk/Bench Top Connection & Software Install. (cont)
4.5.1 Getting Ready To Test PLC Inputs and Analog outputs to drives:
IMPORTANT: – All the limit switches and Estop switch must be a normally closed
switch. In addition, your servo drives must be either be capable of accepting an active
low enable or you will need invert the signals using either external relays or any of
the available PLC relay outputs. The Mach configuration settings for active
high/low have NO effect on the states of the GPIO4D I/O.
Before you can test the PLC and drive interface, you must first jumper the Faults, Limits,
Estop and Enable PLC Inputs and disable encoder faults and stall detection in the
software. When this section of testing is complete, leave any fault, limits or encoder inputs
which are not being used being used jumped and/or disabled in software.
4.5.2 Inserting the correct SIPS for testing. SIPS (Single Inline Package) are resistor
packs which configure the PLC inputs for use with a specific voltage. The GPIO4D can be
configured for use with +/- 5VDC, +/- 12VDC or +/- 24VDC devices. For testing purposes,
we will be using the +12VDC and 12 Com power which are available on the power header
(H6) on the GPIO4D. For testing purposes install the 1K SIPS on the PLC inputs.
Before changing SIPS -MAKE SURE THE GPIO4D & MPU11 ARE POWERED OFF!!!
The SIPS are located just behind the input headers (H9 & H10) and each SIP determines
the voltage for a bank of 4 inputs. Values and input voltages are as follows:
470 Ohm SIP = 5 VDC input
1K Ohm SIP = 12VDC input
USE 1K FOR TESTING!!!
2.2K Ohm SIP = 24VDC input
NOTE: The SIPS do not need to be oriented in any particular way when inserted in the
socket.
4. Desk/Bench Top Connection & Software Install. (cont)
4.5.3 Jumping Faults, Limits, Estop and Enable Inputs: In order to test I/O
communications while on the benchtop, install jumpers on the following inputs:
Drive Fault Inputs: Inputs 17-20
Limit Switch Inputs: Inputs 1-8
Emergency Stop Input: Input 11
NOTE: Jumpers should be left on any Limit switch inputs or fault inputs which will not be
used.
4. Desk/Bench Top Connection & Software Install. (cont)
4.5.4 Confirming PLC communications and Brain functionality for limits Click on the
“Diagnostics” tab in Mach3 to view the limit switch and emergency stop inputs as shown
below. This is what the limit switch and Emergency inputs should look like when all the
Emergency stop and limit switch inputs are closed:
4.5.5 Testing Limit Switch Inputs Disconnect and connect the jumpers from the limit
switch inputs (inputs 1-8) and confirm that the states for the limits change to yellow when the
jumper is removed and back to unlit when the jumpers are installed. NOTE: For the time
being, all the limit switch inputs MUST remain for further testing purposes.
4.5.6 Testing Analog Outputs To The Servo Drives Be sure the Estop and Limit Switch
jumpers are installed and that your limit and Emergency I/O look identical to that of the
screen shot above and click on “Reset. This will enable the drives (Enable 1-4). Check to
confirm that the enable LED's are lit to confirm the hardware enable outputs are on. (The
enables LED's are located just behind headers H11-H14). You should now be able to
command a move on an axis in MDI and read a 0-10VDC analog voltage across the Analog
Out and Analog COM terminals for that axis. NOTE: The output will immediately jump to +10
or -10 for a second or so and then drop out with a position or following error fault. The fault
is expected and the motion control is operating correctly. The fault occurs because the
control expects the motors/encoders to respond to the motion command and, because the
motors and encoders are not yet connected, there is no feedback to indicate that the desired
motion is occurring.
5.Connect major components in your cabinet
Connect the major components in your electrical cabinet just you had done on your desktop in
section 4 but wire your 110VAC service through your cabinet disconnect instead of a power strip.
a) Connect the 110VAC from the disconnect to the GPIO4D & MPU11 power supplies
b) Connect the digital power cable from the MPU11 power supply to the MPU11
Connect the digital power cable from the MPU11 power supply to the GPIO4D
c) Connect the CAT5 network cable from the PC to the MPU11
d) Fiber optic cables (2) from the GPIO4D to the MPU11
A
B B
D
C
Power up and test the system as described in section 4 but omit the software installation process.
6. Wiring Basic Sub-systems
6.1 Limit switch and Estop PLC input wiring Limit switches on the GPIO4D should
be a normally closed type switch (contact closure). Use of normally open switches
requires a custom PLC program that can be supplied by the customer or purchased from
AjaxCNC. For the purposes of this document, all limit and estop inputs are assumed to
be normally closed.
Connect your limit switches as shown:
Connect your Estop switch as shown: (no pendant)
6. Wiring Basic Sub-systems (cont)
6.1 Limit switch and Estop PLC input wiring (cont)
Connect your Estop switch with pendant
6. Wiring Basic Sub-systems (cont)
6.2 Limit switch and Estop PLC input testing Power up your system to test the limit
switch and Estop PLC input wiring.
The image above shows the limit switches, in the normally closed and operational state.
The EstopOk input(input 11) is also in the normally closed and operational state.
Trip your Estop and limit switches individually and confirm that the display changes from
unlit to yellow then back to unlit when you trip and release each switch that you have
wired. Confirm that, when none of the limits are tripped, ALL limit switch inputs must be
unlit. If they are not, please check your limit switch wiring. Confirm also that the
Emergency input is off when the switch is not tripped.
Remember – Limit switches and Estop switch MUST be normally closed devices in
order for your control to operate correctly. Changing your ports and pins active
high/low settings changes only the state of the display, it does not provide the
functionality required by the hardware.
Power off your system and continue to section 6.3 “Encoder Wiring”
6. Wiring Basic Sub-systems (cont)
6.3 Encoder wiring Wire the db9 connector that connects your encoders to the MPU11
as shown below:
NOTE: On 3rd party drive/motor systems, in addition to the incremental encoder feedback
there will also often be Tach and/or commutation channels being returned from the
motors. The MPU11 requires only the encoder channels listed above and does not use
the Tach or commutation channels.
When you have completed wiring your encoder cables, connect them to the MPU11 as
shown below and continue to section 6.4 “Testing Encoder Wiring”
Z axis
Y axis
X axis
6. Wiring Basic Sub-systems (cont)
6.3 Testing Encoder Wiring Power up your system to test the encoder wiring. Start the
Mach3 software and select Config → Homing/Limits and make sure that none of the
axes are reversed by confirming that all have a red “x” in the “Reversed” field
To confirm that each encoder is wired correctly, rotate the motor shaft CCW (as seen
while looking at the face of the motor as shown below) and confirm that the position
displayed in DRO becomes more positive while rotating the shaft CCW and becomes
more negative rotating the shaft CW:
Motor face plate
Rotating the shaft CCW increases
the value in the DRO for that axis
Power up and test the system as described in section 4 but omit the software installation process.
6. Wiring Basic Sub-systems
6.4 Wiring the Estop Coil The coil voltage that controls the Estop contactor is routed
through your Estop switch and two fault relays on the GPIO4D. The first relay (Output1)
is controlled by the PLC program and can be used to drop the Estop contactor based on
any PLC event. The second relay (Output17) is used to drop the Estop contactor in the
event that a fault occurs that the PLC is not be able to recognize – such as a hardware
communication error between the GPIO4D and the MPU11. The Estop switch and fault
relays are wired in series so that, if any of the circuits is opened the Estop contactor is
dropped out. The drawings below route 24VAC to the coil of the Estop contactor but the
coil on your contactor may use a different voltage. If that is the case, simply substitute
your supply voltage for the 24VAC shown in the drawings.
6. Wiring Basic Sub-systems
Estop coil circuit with pendant
6.5 Testing Estop Coil Wiring Power up your system to test the etop contactor wiring.
Start the CNC11 software by double clicking on the CNC11 Mill icon on your desktop.
After the MPU11 has initialized, press F10 to continue to the main screen.
Press your Estop switch in and then release it Observe the estop contactor engages
when the Estop switch is released and disengages when Estop is pressed.
Power off the system and proceed to section 7.1 “Wiring 3rd Party Servo Amplifiers to the
GPIO4D ”
7. Wiring 3rd Party Servo Amplifiers to the GPIO4D
7.1 Wiring Enables from the GPIO4D to your 3rd Party Servo Amplifiers. The GPIO4D
provides an “active low” enable to 3rd party Servo amplifiers. This means that, when the
GPIO4D enables an axis, it will pull the signal level of enable output pin down to 5VCOM. If
your 3rd 3rd party Servo Amplifiers require an “active high” enable, you will need to wire it
through an external 5VDC relay or use a PLC output*
*Wiring the enable through a PLC output requires a custom PLC program. An example
is PLC program that peforms this function is available on the AjaxCNC support forum
under the topic: “Current Versions Of Standard MPU11 PLC Programs“
7. Wiring 3rd Party Servo Amplifiers to the GPIO4D (cont)
7.2Wiring GPIO4D External Drive Fault Input The GPIO4D will detect an external drive
fault if the Fault input and Fault COM are not connected to a DC supply voltage and its
opposite. For instance, if the FaultCom is connected to +5VDC, the Fault input must be
connected to 5COM. Which is connected to which does not matter as long as they are
connected to the opposite of each other. I.e. if the Fault input is connected to +24VDC,
the Fault COM must be connected to 24COM or an external drive fault will be detected
the axis will be disabled by the GPIO4D.
7.3 Wiring GPIO4D Analog Control Voltage If no faults are detected, the GPIO4D
provides -10 to +10VDC for analog control of up to 4 3rd party servo amplifiers. When
wiring the analog control voltage -always- use twisted pair wiring between the GPIO4D
and the servo amplifier.
8. Configure motors, encoders and limit switches in software
8.1Configuring motors to move in the correct direction It is important to understand
that correct motor direction is determined by the motion of the tool relative to the part,
this is not necessarily the same as the motion of the table. For axes that move the table
while the tool remains stationary such as the X & Y axes on a typical Bridgeport type
knee mill, the table motion is the opposite of the “tool motion”. For axes that move the
tool, such as the quill on a knee mill, axis motion is the same as the tool motion. The
illustrations below describe this concept.
Correct tool motion for each axis
Difference between table motion and tool motion on X axis of knee mill
In the above illustration, the tool is moving in the X+ direction relative to the part
while the table moves to the left.
8. Configure motors, encoders and limit switches in software
8.1 Configuring motors to move in the correct direction (cont.) Jog each axis and
determine if the axis is moving in the correct direction. To determine this, observe that
the DRO counts more positive while moving an axis in the positive direction and that it
counts more negative while moving in the negative direction. To correct for an axis that
is moving in the wrong direction, click Configure → Homing/Limits to display the screen
below. To reverse the direction of any axis, click on the “reversed” field to display a
green check mark:
8. Configure motors, encoders and limit switches in software
8.2Configuring motors to move the correct distance Configuring your motors to move
the correct distance involves calculating the number of encoder counts (“Steps per”) in
an inch of travel. To determine this, set up a block on the table as shown below. Use a
standard or anything that you can accurately measure, a 6” parallel works nicely as
shown below:
1. Jog in slowly from 1
direction to take up lash
2. Zero indicator and axes
3. MDI Z to .5” to clear
4. MDI command X to 6”
5. Read indicator to measure
distance traveled
6. Compute and enter new
“Steps per”
Set X0, Y0, Z0
Spindle
Block measured 6.0000”
How to compute “Steps per”: (Found in Config->Motor Tuning)
Commanded distance / Distance moved = multiplier
Multiplier * Current revs/inch = corrected “Steps per”
Ex: Commanded Distance = 6.0000” = .99400~ (multiplier)
Distance moved = 6.0036”
.99400 * 40000 = 39760 New “Steps per”
After you have made your changes, start again at step #1 above to confirm the new settings.
You should be able to accurately position to within a .0001 or so after performing this
procedure 1 or 2 times.
8. Configure motors, encoders and limit switches in software
8.3 Configuring limit switches Use the escape key to go to the main screen. Confirm
that all axes now move in the correct directions, if any do not, perform the procedures in
section 8.1 again. When all axes are moving in the correct directions, jog all axes to the
middle of their physical travel. Trip a limit on an axis -if you tripped the + limit, it should only
let you move the opposite (minus). If it lets you move positive while the plus limit is tripped your limit is incorrectly wired, switch the + and - limit wires for that axis at the GPIO4D to
correct.
8.4 Configuring backlash compensation A note on backlash and backlash
compensation: Before configuring the backlash compensation in the control, every effort
should be made to reduce the mechanical lash in your machine to less than .001”. The
“electronic” backlash compensation provided by the control will help, especially in point to
point moves, but the overall accuracy of your machine is determined purely by the amount
mechanical lash in the machine.
NOTE: Before measuring backlash, make sure any existing backlash compensation is
removed. As shown below, always use MDI and slow feedrates when measuring
backlash. If you jog or using faster feedrates, your measurements may be inconsistent
due to the inertia of the table.
1. Zero indicator and axis
2. MDI G1 X- .025 F.5
3. MDI G1 X0 F.5
4. Read indicator to measure
backlash
5. Enter backlash amount
To enter backlash compensation values:
Config → Config Plugins -> Ajax Plugin → Config
Spindle
9. Wiring Auxiliary Sub-systems
9.1 Lube Pump Wiring The example uses the standard 110vac Lube Pump.
LUBE PUMP SUBCIRCUIT
The typical lube pump circuit
consists of two parts: The first part
is the control of the lube pump itself
which is controlled by output 2
sending 110VAC to the lube pump.
The second part is the low lube
alarm signal which gets wired to
input 9. The low lube signal tells the
control to produce a “405 Low lube”
alarm which inhibits the control from
starting a new job until the lube
pump is refilled and the alarm is
cleared.
When wiring your lube pump it is
important to know which type of lube
pump you have so that you configure
it correctly. Typically lube pumps
come in one of 3 types:
The Mechanical Cam Actuated Lube
Pump is based on a simple
mechanical plunger riding on a clock
motor driven cam. The advantage of
this type of lube pump is that it is
reliable and it remembers where it
was and how much run time has
been accumulated even between
power cycles. So that you actually
get lube ever 10 minutes for 5
seconds of machine use.
Electronic Lube Pumps try to imitate the mechanical cam pumps but often forget where in sequence they were
when powered off. There are two types of Electronic lube pumps, “lube first” which pumps lube immediately
after power on. Which typically results in too much lube. The second type is “lube last”, this type waits a set
amount of time before lubing the machine. The problem with is type is on small jobs your machine may never
get any lube, therefore possible damaging the machine. To avoid this some people wire the lube last type to
get power all the time which then results in too much lube.
Direct controlled lube pumps are controlled by the control via the PLC program and the software. With this
type the lube pump is not responsible for the timing of the pump actuation. This method is the best for reliable
even lubing of your machine. Centroid Users see Tech Bulletin #171 and Parameter 179 in the operators
manual for further explanation.
9. Wiring Auxiliary Sub-systems
9.2Coolant Pump Wiring
Coolant Flood Pump Sub-circuit Diagram
This sub-circuit shows how to hook up a 3 phase Flood Pump. Because the
pump draws higher current at 220V a Flood Contactor PART# 3959 is needed.
Notice the Quencharc PART# 1819 on the coil of the contactor, this prevents
electrical noise when the coolant flood is cycled on and off. A thermal overload is
also shown, this part protects the motor by opening the circuit if it stalls for any
reason, such as dips in the pump.
NOTE: This diagram depicts the 24VAC wired through the NC contacts on the
overload section of the contactor. The overload protection circuit on your
existing contactor may be labeled differently or there may be no overload
protection.
9. Wiring Auxiliary Sub-systems
9.3 Spindle Wiring
9.3.1 Spindle Contactor Wiring
9. Wiring Auxiliary Sub-systems
9.3.2 Spindle Inverter Wiring -AutomationDirect GS2
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