Mach3 ALLIN1DC Mill

Installation
Last revised 2011-02-22 (277)
Table of Contents
1. Introduction
2. What's included
3. Order Of Installation
4. es!"#enchto$ connection% soft&are and net&or! installation and confi'uration
(. )ountin' *a+or co*$onents in electrical ca,inet
-. .onnectin' and testin' *a+or co*$onents in the electrical ca,inet
7. Wirin' ,asic su,-s/ste*s
0. .onfi'urin' *otors% encoders and li*it s&itches in soft&are
1. Wirin' au2iliar/ su,-s/ste*s
1.1 Lu,e $u*$
1.2 .oolant $u*$
1.3 3$indle
Introduction
This manual describes how to install the AjaxCNC (Computer Numerical Control) system. It is
strongly recommended that you follow each step in order without sipping steps. The !C based
AjaxCNC system pro"ides # to $ axis closed loop ser"o interpolated motion% controlled by industry
standard &'Codes. The system is intended for CNC control of milling machines% routers% lathes%
flame% plasma% laser(water jet cutters% and other speciali)ed applications. The AjaxCNC system is
intended for use by competent installers% retro'fitters% and machine tool builders who want to do
their own installation. This installation manual is not intended for casual end users.
Before You Begin:
Installing your new Ajax CNC** based A++IN*,C -ystem is a straight forward process if you follow
the directions included here. .efore getting started% please tae the time to familiari)e yourself with
the schematics% manuals and installation instructions.
/hile doing the installation% it is very important that you follow the instructions exactly. ,oing the
installation incrementally and testing as you go will allow you to immediately isolate the cause of
any problems that you may run into. A troubleshooting procedure is included for each section of
the installation so that if you do run into any problems% you will be able to 0uicly isolate the cause
and correct it. In addition tot he troubleshooting procedures you can find answers to many
0uestions in our support forum www.ajaxcnc.com(ajaxbb
If you run into a problem that you can not sol"e using the troubleshooting procedure or through the
support forum% please fill out the appropriate troubleshooting form included in Appendix A and send
it "ia email to tech1ajaxcnc.com. 2ee based phone support is also a"ailable if needed. !lease
see http3((ajaxcnc.com(tech4support.htm for details.
2. What's included:
5ae sure your it is complete and has not been "isibly damaged in shipment. The basic
Allin*,C it includes3
The Ajax CNC** .ased CNC 6it you purchased contains3 7ty
*. A++IN*,C Integrated 5otion control% # axis -er"o ,ri"e and !+C * ea.
8. **9:AC power cable
#. Connectors(pins(-I!- for I(;
<..Installation(=lectronic ,ocumentation C, * ea.

#. ;rder ;f Installation
Section 4 - Desktop/Bench top connection '
4.1 Connecting the major components
4.2 !ower up for the first time
4.3 -oftware installation and configuration in /indows >
4.4 Testing !C% 5!?** and !+C communications
Section 5 onnect !nd test the "!#or co"ponents in the e$ectric!$ c!%inet
Section & - 'iring B!sic Su%-s(ste"s
&.1 /iring limit switches and =stop !+C Input
$.2 Testing limit switches and =stop input
$.3 /iring =stop coil
$.4 /iring encoders
$.5 Testing encoders
$.& /iring motors and motor power
$.) Testing motors and motor power
Section ) - onfiguring "otors* encoders !nd $i"it s+itches in soft+!re
).1Configuring motors to mo"e in the correct direction
>.8 Configuring encoders
>.# Temporarily )ero out limit and home switch !+C input "alues
).4 Configuring your motors to mo"e the correct distance
>.@ Configuring baclash compensation
>.$ Configuring limit and home switches
Section , - 'iring -u.i$i!r( Su%-s(ste"s
A.1 +ube pump
A.2 Coolant pump
,.3 -pindle
A.3.1 Be"ersing Contactors
A.3.2 :2,(In"erter /iring C Automation,irect &-8

<. ,es(.ench Top Connection D -oftware Install.
Desktop/Benchtop configur!tion !nd testing
The most important thing you can do to insure a trouble free installation is to follow the ,estop
configuration and testing procedure closely. It only taes about <@ minutes of your time and e"ery
major subsystem will be tested during the destop configuration. There are only 8 connections
needed to get started with the destop configurationE ' **9:AC AC to the power supply of the
A++IN*,C and the ethernet cable to your !C.
6eep in mind that if you run into any issues when you are installing the control on your machine%
you will be referred bac to the destop installation and configuration section. !lease do /01 sip
this step. !erforming the complete destop configuration will sa"e you time in the long run.
Do perform the installation in the exact order outlined in these instructions.
Do test as you go.
Do pay close attention to all instructions and follow them exactly.
Do mae sure you download the latest "ersion of software.
Do mae use of the Ajax support forum at3 www.ajaxcnc.com(ajaxbb
4. Desk/Bench 1op onnection 2 Soft+!re Inst!$$. 3cont4
4.1 onnecting the "!#or co"ponents The first step in the installation is to connect the major
components together on your destop as depicted in 2ig. # below. .e sure that your surface is
non'conducti"e and that you use a power strip so that all you components are powered on and off
at the same time. /hen e"erything is connected% your setup should loo similar to the photo in
2ig. < on the following page. At this point% the only connections that should be made are3
a) The **9:AC from the power strip to the A++IN*,C !C power supply.
b) CAT@ networ cable from the !C to the A++IN*,C





!C
!ower -trip
=thernet CAT@
!C
!ower -trip
**9:AC
=thernet CAT@
<. ,es(.ench Top Connection D -oftware Install. (cont)
4.3 Soft+!re Inst!$$!tion !nd configur!tion on 'indo+s 56 /ith your destop
configuration completely powered up as described in section <.8. Install the 5ach#
-oftware and configure /indows to communicate with the 5!?** hardware
4.3.1 Inst!$$ing 7!ch3 Soft+!re Install mach to the default location
Se$ect the 7!ch3 p!ck!ges do not inst!$$ the p!r!$$e$ port dri8ers
4. Desk/Bench 1op onnection 2 Soft+!re Inst!$$. 3cont4
4.3.1 Inst!$$ing 7!ch3 Soft+!re 3cont4
/o custo" profi$e is needed* the -#!. p$ug-in +i$$ cre!te it9s o+n
4.3.2 0%t!ining !nd inst!$$ing the $!test -#!. 7!ch3 p$ugin 8ersion
The installation program% setup'mach'ajax'"F.FF.exe for the Ajax 5ach# plug'in can be
found in the root directory on the ,:, supplied with all Ajax 5!?** systems is also
a"ailable for downloadG from the AjaxCNC website at3
http3((ajaxcnc.com(tech(downloads(software(. It is recommended that you chec to mae
sure that you ha"e the latest "ersion of the plug'in before installation.
If you are running from the ,:,% double clic Hsetup'mach'ajax'"F.FF.exe I to begin the
software installation. If you downloaded the software from the website% extract the files to a
local directory and then run Hsetup'mach'ajax'"F.FF.exeI.
/hen the installer begins% you will be presented with a list of checboxes to select which
pacage C 5ill% +athe% 5ill ,emo or +athe ,emo. -elect only H5illI and clic HnextI. /hen
prompted for the installation dri"e% lea"e it at the default location (c3J)% clic HnextI. /hen the
CNC** installation is complete% clic HNextI and then H2inishI.
GBe0uires username and password to access lin. If you do not now your username and password% please
email tech1ajaxcnc.com to re0uest it. /hen emailing% be sure to pro"ide the customer name and address
that your 5!?** system was purchased under or your system serial number. /e cannot process your re0uest
without this information.
4. Des!"ench To# Connection $ %oft&a'e Install. (cont)
4.3.2 0%t!ining !nd inst!$$ing the $!test -#!. 7!ch3 p$ugin 8ersion 3cont4
Se$ect the %r!ins to %e inst!$$ed. Se$ect the def!u$t %r!ins !nd* if (ou h!8e ! #og
pend!nt* inst!$$ the pend!nt Br!ins !s +e$$* don9t se$ect "pg* 4th !.is etc... +e +i$$
inst!$$ those $!ter
onfigure (our net+ork !d!pter )a!e sure /ou allo& the installer to set the I6 address
(10.1-0.41.1) of the ada$ter in /our 6. or it &on't ,e a,le to see the )6711. 8O9:; If /ou have
*ore than 1 net&or! ada$tor installed - select the ada$tor &ith the I6 adddress that ,e'ins &ith
1-1.222.222.222 as sho&n ,elo&
<. ,es(.ench Top Connection D -oftware Install. (cont)
4.4 St!rting 7!ch for the first ti"e
.efore running 5ach# software for the first time% you must first configure /indows firewall to
allow 5ach# access to the networ to communicate with the 5!?** hardware.

4.4.1 onfigure 'indo+s :ire+!$$ 1o -$$o+ 7!ch3 to o""unic!te 'ith 1he 76;11.
,ouble clic the CNC** 5ill icon on your destop to start the CNC** software. ,epending
on your K! /indows 2irewall configuration% you may see the window below when you first
try to run 5ach#. Lou must clic H?nblocI to allow 5ach# to communicate with your
5!?** and for 5ach# to operate correctly.
;nce 5ach# has started and initiali)ed the 5!?**% you should see MAjax Nardware
detectedM in the bottom left of the 5ach screen.
ongr!tu$!tions< You h!8e successfu$$( configured (our 6 !nd 7!ch3 to
co""unic!te +ith the 76;11 "otion contro$$er.
<. ,es(.ench Top Connection D -oftware Install. (cont)
4.4.2 onfiguring the -#!. 7!ch3 p$ug-in -elect Config from the top menu in 5ach% when
the plug'in pop'up windows comes up% select the yellow C;N2I& box next to Ajax !lugin3
This brings up the Ajax !lugin configuration screen. Changing the "alue in M-top on =ncoder
=rrorM from * to 9 will pre"ent a fault from being generated while we test without the
encoders connected% lea"e the M5essage on =ncoder =rrorM "alue set to *. This will issue a
warning message on the screen to remind us that the encoders are not connected but it
wonOt trigger any faults3
<. ,es(.ench Top Connection D -oftware Install. (cont)
4.5onfir"ing 6= co""unic!tions !nd Br!in function!$it( for $i"its Clic on the
H,iagnosticsI tab in 5ach# to "iew the limit switch and emergency stop inputs as shown
below. This is what the limit switch and =mergency inputs should loo lie when all the
=mergency stop switch and limit switches are closed3
Toggle the H+imit ,I! -witchesI located on the A++IN*,C to defeat and enable the limit
switch inputs while obser"ing the states of 5*'5# HPI and H'I inputs. -etting a switch to the
HupI position defeats (shorts) that limit input% setting it to the HdownI position enables it.
/hen an input is closed% the +=, will be ;22. /hen an input is open (tripped) the +=, will
be lit (yellow). It should be noted that setting a limit defeater for an input to the up position
is electrically the same as closing that input as shown below.
After confirming operation for each limit input%
lea"e the defeater in the HupI position for any
axis D direction that you will N;T be wiring a
limit switch to.
4. Desk/Bench 1op onnection 2 Soft+!re Inst!$$. 3cont4
4.& onfiguring 6= inputs to "!tch the 8o$t!ge of (our de8ices:
The A++IN*,C !+C inputs can be wired for @% *8 or 8<:,C de"ices in either sining
or sourcing configuration. In laymanOs terms% this simply means that you can wire
either positi"e ,C "oltage or the ground (or common) into an input as long as you
put its opposite into the common for the input(s). In the diagram abo"e% because
P*8:,C is wired through the limit switches into inputs *'$ so the *8: ground
(common) must be wired to C;5 IN!*'< D C;5 IN! @'A.
I760>1-/1<<<< 7!ke Sure to the 8!$ue of the SI6S in SI61-4
"!tch the 8o$t!ge 8!$ues of (our input de8ices.
<>9 ;hm -I! Q @ :,C input
1? 0h" SI6 @ 12AD input
8.86 ;hm -I! Q 8<:,C input
N;T=3 The -I!- do not need to be oriented in any particular way when inserted on the
socet.
4. Desk/Bench 1op onnection 2 Soft+!re Inst!$$. 3cont4

4.) 1esting B/o :!u$tC 0utput. ;utput number *% labeled as HNo 2aultI on the
A++IN*,C is pre'configured by the !+C program to turn off when the !+C detects
that any of the following has occurred3 The =stop switch is pressed or an encoder%
spindle or lube fault is detected. /ith the =stop jumped and the lube% spindle and
encoder faults disabled in software% confirm that you ha"e continuity between the pins
labeled HNo 2ault ComI and HNo 2aultI on ;utput *.
Chec for continuity


@. 5ounting major components in your electrical cabinet
5.16!ne$ =!(out .elow is a suggested layout for the major components on your electrical panel.
This layout eeps the hea"ier components (transformer) at the bottom to eep the enclosure from
being top hea"y and separates power from signal wiring where"er possible. and helps eep the
distance short when routing the ,C motor power (/e recommend that motor power routing be less
than $ feet)


7ounting the ter"in!$ strip in the
"idd$e pro8ides e!s( !ccess to
!nd fro" !n( co"ponent
7ounting the c!p !nd %ridge
under the -==I/1D $e!8es
"ore roo" for cont!ctors in
other !re!s of the c!%inet


$. Connect major components in your cabinet
Connect the major components in your electrical cabinet just you had done on your destop in
section < but wire your **9:AC ser"ice through your cabinet disconnect instead of a power strip.
a) The **9:AC from the disconnect to the A++IN*,C !C power supply
b) CAT@ networ cable from the !C to the 5!?**





!C
!ower -trip
=thernet CAT@
!C
!ower -trip
**9:AC
=thernet CAT@
>. /iring .asic -ub'systems
).1 =i"it s+itch !nd Dstop 6= input +iring +imit switches on the A++IN*,C 7;S1 be a
normally closed type switch (contact closure). This is because the A++IN*,C electrically disables
motor rotation in one direction when a limit switch is open. The limit switch inputs (inputs *'$) are
dedicated and can not be used as a general purpose input. Any limit switch input that you will not
be using "ust be disabled in order for your system to operate properly. To disable a limit switch
input% you can either pu$$ ;6 the +imit ,ip -witch for that axis and direction as shown in the photo
below left or jumper the input to the common for that axis as shown below right (photo depicts all
limits and =stop input jumpered and defeated). N;T=3 The two methods are electrically identical3
onnect (our $i"it s+itches !s sho+n:

). /iring .asic -ub'systems (cont)
).1 =i"it s+itch !nd Dstop 6= input +iring 3cont4
/01D: 1he +iring for the Dstop 6= %e$o+ depicts ! 24AD supp$(. If (our supp$( 8o$t!ge
differs* si"p$( su%stitute (our 8o$t!ge !nd ch!nge SI62 !ccording$(. See section 4.& for
infor"!tion on se$ecting the correct SI6 8!$ue to "!tch (our $ogic 8o$t!ge.
Dstop 6= input +iring The =stop input (input **) on the A++IN*,C "ust be wired to a normally
closed switch (contact closure). /hen the =stop input is open% all motors are disabled.
Dstop 6= input +iring no pend!nt
). /iring .asic -ub'systems (cont)
).2 Dstop 6= input +iring +ith pend!nt
).3 =i"it s+itch !nd Dstop 6= input testing !ower up your system to test the limit switch and
=stop !+C input wiring. -tart the CNC** software by double clicing on the CNC** 5ill icon on
your destop. After the A++IN*,C has initiali)ed% press 2*9 to continue to the main screen. Now%
hold down the HaltI ey and press the HiI ey at the same time to bring up the real'time I(; display.
The image to the right shows the limit switches% inputs *'$% in the upper left in the normally closed
and operational state.
The =stop input% input **% is also in the normally closed and operational state.
Trip your =stop and limit switches indi"idually and confirm that the display changes from green to
red and then bac to green when you trip and release each switch that you ha"e wired. Confirm
that% when none of the limits are tripped% A++ limit switch inputs (*'$) 5?-T be green. If they are
not% please chec your limit switch wiring or re"iew section <.<.8 to defeat your unused limit switch
inputs. Confirm also that the =stop input% input **% is green when the switch is not tripped.
heck the /o :!u$t re$!( (;utput *) ?se an ohm meter to confirm that the relay opens when the
estop switch is pressed and closes when it is released.

).4 Dncoder +iring /ire the dbR connector that connects your encoders to the A++I*,C as
shown below3
>.$ To confirm that each encoder is wired correctly% rotate the motor shaft CC/ (as seen while
looing at the face of the motor as shown below) and confirm that the position displayed in the
,B; becomes more positi"e while rotating the shaft CC/ and becomes more negati"e rotating
the shaft C/3

5otor face plate

Botating the shaft CC/ increases
the "alue in the ,B;
>. /iring .asic -ub'systems
).) 'iring the Dstop oi$ The coil "oltage that controls the =stop contactor is routed through
your =stop switch and the No 2ault relay (;utput*). /ith the =stop switch and No 2ault relay
wired in series% if either opens% motor power will be remo"ed from the A++IN*,C during an =stop
or other fault condition. The drawings below route 8<:AC to the coil of the =stop contactor but the
coil on your contactor may use a different "oltage. If that is the case% simply substitute your supply
"oltage for the 8<:AC shown in the drawings.

). /iring .asic -ub'systems (cont)
)., 1esting Dstop oi$ 'iring !ower up your system to test the estop contactor wiring. -tart the
CNC** software by double clicing on the CNC** 5ill icon on your destop. After the A++IN*,C
has initiali)ed% press 2*9 to continue to the main screen.
6ress (our Dstop s+itch in !nd then re$e!se it ;bser"e the estop contactor engages when the
=stop switch is released and disengages when =stop is pressed.
!ower off the system and proceed to section >.> H/iring 5otors and 5otor !owerI
)., 'iring 7otor 6o+er. /ire the motor power from your ser"o power supply to the A++IN*,C
as shown below3
).,.1 1esting 7otor po+er.
1. Do /01 connect (our "otor po+er c!%$es or tr( to #og (our "otors unti$ instructed
to do so in the procedure %e$o+.
2. Before po+ering up the s(ste"* push (our Dstop s+itch in.
3. 6o+er up (our s(ste". St!rt the /11 soft+!re %( dou%$e c$icking on the
/11 7i$$ icon on (our desktop.
1est (our ser8o po+er supp$( +iring 3"otor po+er4 !s fo$$o+s:
).,.1 7e!sure the output 8o$t!ge of (our ser8o po+er supp$( /ith the =stop switch
pushed in% measure the ,C "oltage at the output of the ser"o power supply (if we supplied
the ser"o power supply% chec across the terminals mared HPI and H'I on the cap board.) If
using an pre'exisiting ser"o power supply% usually a good place to measure is across the
terminals on the big capacitor (cylinder about the si)e of a soda can). Confirm that the
"oltage is between 89'*#9:,C. .efore continuing% !+=A-= double chec your wiring for
:5P and :5' to mae sure that they go to the correct terminals on the A++IN*,C.
).,.2 >e$e!se Dstop* press B>esetC !nd "e!sure the D 8o$t!ge !t A7E 2 A7-
/hen you release =stop and press HBesetI% you should hear the =stop contactor pull'in.
5easure the "oltage on the :5P and :5' terminals on the N8 header on the A++IN*,C
and confirm that the ,C "oltage is the same that was measured at the output of the ser"o
power supply.
).,.3 6ush Dstop in !nd po+er off.
).,.4 onnect "otor c!%$es to "otor po+er connectors on -==I/1D !s sho+n
%e$o+.

).,.1 1esting 7otor po+er 3cont4
).,.5 !ower up the system and then start 5ach#
).,.& 7o8ing "otors for the first ti"e If you are using a jog pendant% mae sure that the
2ast(-low jog +=, (located between the K' D KP jog eys) is you are using the
eyboard to jog% press the left or right arrows to jog the K% up and down arrows to jog L
and !age?p(!age,own to jog S.
/01D: If !n !.is i""edi!te$( #u"ps in one direction !nd gets
! 6osition Drror or :u$$ 6o+er 'ithout 7otion 2irst% double chec
your encoder connection and confirm that the encoder for the axis in 0uestion is counting smoothly
and in the correct direction% then try switching the P D ' leads for that axis where the motor cable
connects to the A++IN*,C. If the axis is oscillating (jumps bac and forth in both directions) than
the issue is tuning related. !lease see the tuning section of the manual for more information.
,. onfigure "otors* encoders !nd $i"it s+itches in soft+!re
,.1onfiguring "otors to "o8e in the correct direction It is important to understand that
correct motor direction is determined by the motion of the tool relati"e to the part% this is not
necessarily the same as the motion of the table. 2or axes that mo"e the table while the tool
remains stationary such as the K D L axes on a typical .ridgeport type nee mill% the table motion
is the opposite of the Htool motionI. 2or axes that mo"e the tool% such as the 0uill on a nee mill%
axis motion is the same as the tool motion. The illustrations below describe this concept.

orrect too$ "otion for e!ch !.is
Difference %et+een t!%$e "otion !nd too$ "otion on 5 !.is of knee "i$$
In the !%o8e i$$ustr!tion* the too$ is "o8ing in the 5E direction re$!ti8e to the p!rt
+hi$e the t!%$e "o8es to the $eft.
,. onfigure "otors* encoders !nd $i"it s+itches in soft+!re
,.1 onfiguring "otors to "o8e in the correct direction 3cont.4 Tog each axis and determine if
the axis is mo"ing in the correct direction. To determine this% obser"e that the ,B; counts more
positi"e while mo"ing an axis in the positi"e direction and that it counts more negati"e while
mo"ing in the negati"e direction. To correct for an axis that is mo"ing in the wrong direction% clic
Configure U Noming(+imits to display the screen below. To re"erse the direction of any axis% clic
on the Hre"ersedI field to display a green chec mar3
,.2 1e"por!ri$( dis!%$e $i"it s+itch Br!ins -elect ;perator'V.rain Control and clear the chec
mar from the HAjax +imit InputsI D HAjax +imit NandlingI brains% clic HBeload All .rainsI and then
H;6I
,. onfigure "otors* encoders !nd $i"it s+itches in soft+!re
,.3onfiguring "otors to "o8e the correct dist!nce Configuring your motors to mo"e the
correct distance in"ol"es calculating the number of encoder counts (H-teps perI) in an inch of
tra"el. To determine this% set up a bloc on the table as shown below. ?se a standard or anything
that you can !ccur!te$( measure% a $I parallel wors nicely as shown below3

Fo+ to co"pute BSteps perC: 3:ound in onfig-G7otor 1uning4
Commanded distance ( ,istance mo"ed Q multiplier
5ultiplier G Current re"s(inch Q corrected H-teps perI
=x3 Commanded ,istance Q $.9999I Q .RR<99W (multiplier)
,istance mo"ed Q $.99#$I
.RR<99 G <9999 Q #R>$9 New H-teps perI
After you ha"e made your changes% start again at step F* abo"e to confirm the new settings. Lou
should be able to accurately position to within a .999* or so after performing this procedure * or 8
times.

-pindle
-et K9% L9% S9
*. Tog in slowly from *
direction to tae up lash
.loc measured $.9999I
8. Sero indicator and axes
#. 5,I S to .@I to clear
<. 5,I command K to $I
@. Bead indicator to measure
distance tra"eled
$. Compute and enter new
H-teps perI
,. onfigure "otors* encoders !nd $i"it s+itches in soft+!re
,.4 onfiguring $i"it s+itches ?se the escape ey to go to the main screen. Confirm that all
axes now mo"e in the correct directions% if any do not% perform the procedures in section A.* again.
/hen all axes are mo"ing in the correct directions% jog all axes to the middle of their physical
tra"el. Trip a limit on an axis 'if you tripped the P limit% it should only let you mo"e the opposite
(minus). If it lets you mo"e positi"e while the plus limit is tripped ' your limit is incorrectly wired%
switch the P and ' limit wires for that axis at the ,C#I;. to correct. /hen you ha"e done this for
all axes% go bac into the .rain Control (-ection A.8) re'enable HAjax +imit InputsI D HAjax +imit
NandlingI brains% clic HBeload All .rainsI and then H;6I.
,.5 onfiguring %!ck$!sh co"pens!tion A note on baclash and baclash compensation3
.efore configuring the baclash compensation in the control% e"ery effort should be made to reduce
the mechanical lash in your machine to less than .99*I. The HelectronicI baclash compensation
pro"ided by the control will help% especially in point to point mo"es% but the o"erall accuracy of your
machine is determined purely by the amount mechanical lash in the machine.

N;T=3 .efore measuring baclash% mae sure any existing baclash compensation is remo"ed.
As shown below% always use 5,I and slow feedrates when measuring baclash. If you jog or
using faster feedrates% your measurements may be inconsistent due to the inertia of the table.


1o enter %!ck$!sh co"pens!tion 8!$ues:
Config U Config !lugins 'V Ajax !lugin U Config

-pindle
*. Sero indicator and axis
8. 5,I &* K' .98@ 2.@
#. 5,I &* K9 2.@
<. Bead indicator to measure
baclash
@. =nter baclash amount
H. 'iring -u.i$i!r( Su%-s(ste"s
=u%e 6u"p 'iring
<A
;?T *#
2+;;,
2+;;, C;5
+?.= C;5
+?.=
-!IN ,IB C;5
N;
NC
;?T 8
N;
NC
-!IN B=-=T C;5
;?T *@
N*$
N89
BAN&= INR
B;T AC6 IN#*
C;55;N
,!< IN!?T IN*<
B=+ -/ IN8@
,!< ,=T=CT IN*@
B;T N5 IN#9
-!IN 2+T IN8@
C;55;N
C;55;N
+;/ +?.= IN*A
P@ :;+T-
ACN
ACN
A+AB5 N;
A+AB5 C;5
A+AB5 NC
&N,
IN!?T C;55;N
P@:,C
;pto isolator
IN!?T
TL!ICA+
IN!?T
+?.=
!?5!
AC !;/=B **9:
2;B +?.= !?5!
,C#I;.
F /
H. 'iring -u.i$i!r( Su%-s(ste"s
oo$!nt 6u"p 'iring
<A
;?T *#
2+;;,
2+;;, C;5
+?.= C;5
+?.=
-!IN ,IB C;5
N;
NC
;?T 8
N;
NC
-!IN B=-=T C;5
;?T #
;?T *@
P8<:
C;I+
T8 T# T*
+8
+#
+*
A8
A*
!;/=B 2;B 2+;;,
C;NTACT;B C;I+
+8 +# +*
T8 T# T*
R> RA R@ R$
,C#I;.
2+;;,
C;NTACT;B
TN=B5A+
;:=B+;A,
!B;T=CT;B
# !NA-= !;/=B
2;B 2+;;, !?5!
2&
7?=NCNABC
# !hase
2lood !ump
889"1#A5!-
N*$
oo$!nt :$ood 6u"p Su%-circuit Di!gr!"
This sub'circuit shows how to hoo up a # phase 2lood !ump. .ecause the
pump draws higher current at 889: a 2lood Contactor !ABTF #R@R is needed.
Notice the 7uencharc !ABTF *A*R on the coil of the contactor% this pre"ents
electrical noise when the coolant flood is cycled on and off. A thermal o"erload is
also shown% this part protects the motor by opening the circuit if it stalls for any
reason% such as dips in the pump.
/01D: This diagram depicts the 8<:AC wired through the NC contacts on the
o"erload section of the contactor. The o"erload protection circuit on your
existing contactor may be labeled differently or there may be no o"erload
protection.
H. 'iring -u.i$i!r( Su%-s(ste"s
H.3 Spind$e 'iring
Spind$e ont!ctor 'iring

3 6h!se In
1o Spind$e 7otor
T8 T* T#
+8 +* +#
C;I+
A*
A8
T8 T* T#
+8 +* +#
C;I+
A*
A8 T8 T* T#
+8 +* +#
R@
NC
R>
N;
R$
NC
RA
N;
TN=B5A+
;:=B+;A,
!B;T=CT;B
-!IN CC/
C;NTACT;B
-!IN C/
C;NTACT;B
8A
,BI:=
2A?+T
;?T <
;?T *@
<A
;?T *#
2+;;,
2+;;, C;5
+?.= C;5
+?.=
-!IN ,IB C;5
N;
NC
;?T 8
N;
NC
-!IN B=-=T C;5
;?T #
8A
;?T *@
N*$
,B: 2+T B+L8
,B: 2+T B+L*
5I-T C;5
5I-T
-!IN =N C;5
N;
NC
N;
NC
;?T #9 C;5
N*>
,C#I;.
N89
BAN&= INR
B;T AC6 IN#*
C;55;N
,!< IN!?T IN*<
B=+ -/ IN8@
,!< ,=T=CT IN*@
B;T N5 IN#9
-!IN 2+T IN8@
C;55;N
C;55;N
+;/ +?.= IN*A
P@ :;+T-
-!IN C/
-!IN CC/
8<C;5 8<:AC
H. 'iring -u.i$i!r( Su%-s(ste"s
Spind$e In8erter 'iring --uto"!tionDirect IS2
8A
,BI:=
2A?+T
;?T <
;?T *@
<A
;?T *#
2+;;,
2+;;, C;5
+?.= C;5
+?.=
-!IN ,IB C;5
N;
NC
;?T 8
N;
NC
-!IN B=-=T C;5
;?T #
8A
;?T *@
N*$
-!IN AN (P)
,B: 2+T B+L8
,B: 2+T B+L*
5I-T C;5
5I-T
-!IN =N C;5
N;
NC
N;
NC
;?T #9 C;5
N*>
N89
BAN&= INR
B;T AC6 IN#*
C;55;N
,!< IN!?T IN*<
B=+ -/ IN8@
,!< ,=T=CT IN*@
B;T N5 IN#9
-!IN 2+T IN8@
C;55;N
C;55;N
+;/ +?.= IN*A
P@ :;+T-
-!IN C;5 (')
N8
,C#I;.
AC5
A;
P*9:
AI
,C5
,I$
,I@
,I<
,I#
,I8
,I*
B8
B8C
B8;
B*
B*C
B*;
-ee the in"erter manual for connection of
incoming and motor power wires.
IN!?T
C;55;N
IN!?T
P@:,C
TL!ICA+
IN!?T
9.9*
:olts
9.9#
9.9<
*.99
*.9*
*.98
#.99
#.9#
<.99
A.99
R.9A
9.99
!ABA5=T=B
N;
5otor nameplate amps
:A+?=
,epends on motor
9* Q Coast to a stop
98 Q 2re0uency determined
.y 9 C *9"dc on AI*
,epends on motor
5ust be set with a tachometer
to match max spindle speed
,epends on motor
# C @ seconds
# C @ seconds
98 Q =xternal reset
* Q 5otor speed (B!5)
Amps
B!5
sec
?NIT-
-ec
B!5
,=-CBI!TI;N
-ource of f re0uency
command
5otor nameplate "oltage
5otor nameplate B!5
5otor maximum B!5
-topping method
Acceleration time
9* Q =xternal control terminals
,eceleration time
To restore f actory def ault settings set to RR
,I< 5ulti f unction input
Control method
,ri"e display
&-8