MachMotion Apollo III 1000 Series User manual

http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
[phone] • Fax [phone]
Apollo III - 1000 Series

1.1 Overview
The Apollo III is MachMotion's Ethernet motion controller. It uses differential or single-ended step and direction to
control up to 6 axes with full encoder feedback (full closed loop). It also has 16 inputs, 8 outputs, excellent position
resolution, two MPG inputs, and spindle encoder feedback.
See the overview video on our youtube channel:
https://www.youtube.com/watch?v=g3n247P9wUM
1.2 Tools Required
A small, flat head screwdriver is needed for the I/O terminals.
Small needle nose pliers may be needed to move jumpers for the inputs.
1.3 Reference Diagram
Use the diagram below as a reference throughout the manual.
Figure 1 Apollo III Overview
1.4 Status LEDs
The Apollo III has four status LEDs that show the status of the controller’s processor. The LEDs are located close to the
center of the controller. See the figure below.
WARNING!
Improper installation of this motion controller can cause DEATH, INJURY or serious PROPERTY
DAMAGE. Do not attempt to install this controller until thoroughly reading and understanding this
manual.
WARNING!
Do NOT connect DC voltage greater than 48V, or any AC voltage to any part of the Apollo III motion
controller.
It could cause serious damage to the controller.
1 Introduction
WARNING
DO NOT connect 115VAC to any part of the Apollo III motion controller.
It could cause serious damage to the controller.

Figure 2 Status LEDs
Color
Label
Function
Green
PWR
Power is supplied to Apollo III
Orange
CTRL
Apollo III has an enable signal from control
Red
ERR
Apollo III has an error
Green
CPU
Apollo III CPU is running (should be flashing
when power is supplied)
Table 1 - Apollo III Status LEDs
1.5 Specifications
Below are the specifications for the Apollo III motion controller.
Item
Specification
Input Power
24VDC
Max Power Consumption
48W
Motors
6
Step and Direction Axis Control
5V Single Ended and Differential
Connection
RJ45 Connectors and Terminal Blocks
Max Pulse Speed
1.6 MHz
Encoder Feedback
5V Differential
Connection
RJ45 Connectors
Max Frequency
6.25 MHz
Spindle
1
Relay Outputs
Clockwise (CW) and Counterclockwise (CCW)
Analog Signal
0-10VDC
Encoder Feedback
5V Differential
Outputs
8
Voltage
7V-48VDC*
Max Current
250mA**
Commons
2
Inputs
16 (Sinking or Sourcing)
Voltage
2.5V-48VDC
Min Current
2mA

Isolated
Optional
Enable Circuit
2
Hardware Enable
Relay Contacts, 5V Enable, 24V Enable
Drive Enable
Relay Contacts
Emergency Stop Circuit
Normally Closed Connection
Ethernet Port
10/100 MHz
Dimensions
8.32"(L) X 5.75"(W) X 2"(H)
Optimal Temperature Range
32° to 100°F (0° to 38°C)
Table 2 – Specifications for the apollo III motion controller
*Only 24V is provided on the motion controller. Any other voltage must be supplied.
**Commons must be supplied externally. If the commons are using the Apollo III power supply, each output can only
source 125mA.
1.6 Drawing
Below is a drawing of the Apollo III.
Figure 3 - Apollo III Mounting Holes
The controller can be mounted on any solid surface that will be protected from dust and dirt. Use a minimum of 3/8
inch standoffs to prevent electrical shorts.
1.7 Hardware Startup
To power the Apollo III, you must supply 24VDC to the power connection located at the top right of the board as shown
below. The top orange LED labeled Power will turn on.
Scale drawing of the Apollo III and mounting bracket is attached

Figure 4 24V Power Connector
1.8 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.
Figure 5 Profiles
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:
Figure 6 Loader
After double clicking on a profile or opening a profile from Mach4 Loader, a window will come up (Figure 7) asking to
Press Cycle Start to Enable Mach and Home All Axes. Select [Cancel] since motion is not yet possible.
Figure 7 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.
2.1 Apollo lll Cover Removal
All of the drives and external I/O will be wired into the Apollo III. Begin by removing the cover by loosening the black
knobs on the sides.
Figure 8 Apollo III Cover Removed
Next, plug the drive control and encoder cables into the Apollo III motion controller. The drive control connections are
located on the bottom row of the large RJ45 block. The encoder control connections are located on the top row of the
large RJ45 block. See the picture below.
Figure 9 Differential Step and Direction, and Encoder Feedback RJ45 Connections
2.2 Enabling Axes
After the drives are connected to the Apollo III, open up the motion software, and enable the axes as follows:
Note: This may already be setup depending on your system.
1. On the menu bar, click Configure->Control. Then select the Motors tab (pictured below).
2 Axis Setup

Note, if menu options are greyed 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.
Figure 10 motor Setup
3. Press [Apply] to save any changes.
4. 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.
Figure 11 Axis Mapping
5. Press [Apply] and [OK] to save and close.
The system is now set up for motion, however,....
2.3 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.
WARNING
The machine can be crashed very easily. No limit switches have been set up and the units have not
been configured yet.

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; currently unreleased.
2.3.1 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. Linear Compensation - Also known as screw mapping. Allows you to adjust travel distance with
setting offsets to improve accuracy over different parts or sections of the travel. This is often only
needed for high precision machining and typically requires the use of laser for determine very
accurate positions. Contact MachMotion for information on setting this up.
2. Select the drive type of the axis being configured.
3. Select the max motor RPM.
4. Verify the correct drive ratio.
Drive Ratio Apollo III
Drive Type
1
Teco
8
Mitsubishi
64
Yaskawa
1
Stepper
Table 3 - Default Drive Ratio Value
Figure 13 - MachMotion Plugin Calibration Calculator
5. Choose the machine configuration for the axis from the following three options.
Note, if menu options are greyed out (not active/selectable), click the button to disable the system

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)
Enter pinion diameter
Enter the gearing ratio between the shaft and the motor
Enter number of teeth on pinion
Enter the rack pitch
Enter the gearing ratio between the shaft and the motor
1. Ball Screw
2. Rack and Pinion – Pinion Diameter
3. Rack and Pinion – Rack Pitch
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.
2.3.2 Manual Calibration
Figure 14 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.
Typically commanded distance is used. This is where you enter the distance you want it to move and
then record how far it actually moved.
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.