MachMotion Apollo III User manual

Apollo III
MANUAL – MACH3
Specializing in CNC Automation and Motion Control

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11/10/14
R0124
This manual covers the setup and configuration of the Apollo III motion controller connected
to the control using Mach3.
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This manual as well as all other MachMotion manuals can be found at www.MachMotion.com
Copyright © 2014, MachMotion
All rights reserved.
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Apollo III
R0124
Table of Contents
1PART 1: INTRODUCTION.............................................................................................. 8
1.1 Overview.................................................................................................................................8
1.2 Tool Required..........................................................................................................................8
1.3 Reference Diagram ...............................................................................................................8
1.4 Status LEDs ........................................................................................................................... 10
1.5 Specifications....................................................................................................................... 11
1.6 Drawing ................................................................................................................................ 12
1.7 Hardware Startup .............................................................................................................. 12
1.8 Software Startup ................................................................................................................ 13
2AXIS SETUP ................................................................................................................ 14
2.1 Apollo lll Cover Removal................................................................................................... 14
2.2 Enabling Axes...................................................................................................................... 15
2.3 Axis Calibration .................................................................................................................. 16
2.3.1 Manual Calibration.............................................................................................................. 16
2.3.2 Calibration Wizard .............................................................................................................18
2.4 Backlash Calculation........................................................................................................... 19
2.5 Reversing Direction ............................................................................................................. 20
2.6 Slaving an Axis.................................................................................................................... 20
3SPINDLE SETUP........................................................................................................... 21
3.1 Wiring a Spindle ................................................................................................................ 21
3.1.1 VFD from MachMotion.........................................................................................................21
3.1.2 VFD Other Than from MachMotion...................................................................................22
3.1.3 No VFD...................................................................................................................................22
3.2 Spindle Configuration ........................................................................................................ 23
3.2.1 Spindle Pulley Setup............................................................................................................23
3.3Turning on the Spindle ....................................................................................................... 24
3.4 Reversing Direction ............................................................................................................. 24
4LIMITS AND HOMING SETUP...................................................................................... 25
4.1 Homing Setup ...................................................................................................................... 26
4.2 Soft Limits Setup.................................................................................................................. 27
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5INPUT SETUP .............................................................................................................. 28
5.1 Generic Inputs...................................................................................................................... 28
5.2 Wiring Inputs ....................................................................................................................... 29
5.2.1 Standard 24V Inputs ...........................................................................................................29
5.2.2 Sinking Inputs (NPN).............................................................................................................30
5.2.3 Sourcing Inputs (PNP)...........................................................................................................31
5.3 Configuring Inputs............................................................................................................... 31
6OUTPUT SETUP........................................................................................................... 32
6.1 Generic Outputs.................................................................................................................. 32
6.2 Wiring Outputs.................................................................................................................... 33
6.3 Configuring Outputs ........................................................................................................... 34
6.4 Using Outputs ...................................................................................................................... 34
6.5 Mist and Flood Control ...................................................................................................... 35
7ADVANCED OPTIONS ................................................................................................ 35
8PART 2: ADVANCED SETUP ....................................................................................... 40
8.1 Apollo III Network Connection.......................................................................................... 40
8.1.1 Direct Connection..................................................................................................................40
8.1.2 Router Connection................................................................................................................. 42
8.2 Apollo III Software Installation ......................................................................................... 42
8.2.1 Installing Apollo III Plugin and Firmware ......................................................................... 42
8.2.2 Installing VSI Manager........................................................................................................42
8.3 Mach3 Integration .............................................................................................................. 44
8.3.1 Mach3 Startup ......................................................................................................................44
8.4 Apollo III Status Window................................................................................................... 44
8.5 Apollo III Configuration...................................................................................................... 45
9ENABLE CIRCUIT......................................................................................................... 48
9.1 Emergency Stop .................................................................................................................. 48
9.2 Hardware Enable................................................................................................................ 49
9.3 Drive Enable ........................................................................................................................ 51
10 AXES ........................................................................................................................ 53
10.1 Connecting Drives............................................................................................................. 53
10.1.1 Differential Control ...........................................................................................................53
10.1.2 Single-Ended Control........................................................................................................54
10.1.3 Encoder Feedback............................................................................................................. 55
10.2 Configuring Axes.............................................................................................................. 56
10.2.1 Control Parameters ...........................................................................................................57
10.3 Testing Motion................................................................................................................... 58
10.3.1 Test Motion Parameters.................................................................................................... 59
10.4 Backlash Compensation .................................................................................................. 60
10.5 Reversing Direction........................................................................................................... 60
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10.6 Slaving an Axis................................................................................................................. 61
11 SPINDLE.................................................................................................................... 62
11.1 Wiring a Spindle.............................................................................................................. 63
11.1.1 VFD....................................................................................................................................... 63
11.1.2 VFD from MachMotion...................................................................................................... 63
11.1.3 No VFD ................................................................................................................................63
11.1.4 Spindle Feedback..............................................................................................................64
11.2 Configuring the Spindle .................................................................................................. 65
11.2.1 Enabling the Spindle......................................................................................................... 65
11.2.2 Spindle Pulley Setup.........................................................................................................67
11.2.3 Analog Calibration............................................................................................................68
11.2.4 RPM Feedback...................................................................................................................68
11.2.5 Servo Spindle Setup .........................................................................................................68
11.2.6 Turning on the Spindle...................................................................................................... 69
12 MPGS ....................................................................................................................... 69
13 INPUTS ..................................................................................................................... 71
13.1 Wiring Inputs..................................................................................................................... 72
13.1.1 Standard 24V Inputs.........................................................................................................72
13.1.2 High Voltage Sourcing Inputs (PNP)............................................................................... 73
13.1.3 Low Voltage Sourcing Inputs (PNP)................................................................................74
13.1.4 Sinking Inputs (NPN)..........................................................................................................74
13.1.5 Isolated Inputs ....................................................................................................................75
13.2 Configuring Inputs ............................................................................................................ 75
14 OUTPUTS.................................................................................................................. 76
14.1 Wiring Outputs................................................................................................................. 77
14.2 Configuring Outputs ........................................................................................................ 78
14.3 Using Outputs.................................................................................................................... 79
15 APPENDICES ............................................................................................................ 80
15.1 Default Factory Settings ................................................................................................. 80
15.1.1 Default Motor Outputs......................................................................................................80
15.1.2 Default Input Signals.........................................................................................................80
15.1.3 Default Output Signals..................................................................................................... 81
15.2 Apollo III Drawing ............................................................................................................ 83
15.3 Apollo III Case Mount Drawing...................................................................................... 85
16 WARRANTY INFORMATION.................................................................................... 87
16.1 Additional Resources ....................................................................................................... 87
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Part 1:
INSTALLATION & SETUP
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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.
1PART 1: INTRODUCTION
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
1.2 Tool Required
To use the Apollo III, the following items are necessary:
•24VDC Power Supply
•Emergency Stop Circuit
•Control with Mach3 and Ethernet Port
•Small flat head screw driver
MachMotion CNC controls come with the above items, except the screw driver.
1.3 Reference Diagram
Use the diagram below as a reference throughout the manual.
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FIGURE 1 APOLLO III OVERVIEW
WARNING
DO NOT connect 115VAC to any part of the Apollo III motion controller. It could
cause serious damage to the controller.
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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.
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
Apollo III Using Mach3