F.A.Q. Mach3 (Frequently AskedQuestions) PageWhere do I learn more about Mach3 itself?

Game Pad and/or Pendent Issues

Jogging Issue: It keeps jogging and doesn't want to stop

In Motor Tuning (and Setup), what does the 'Step Pulse' and 'Direction Pulse' field do?

In Port Setup and Axis Selection, what does the 'Kernel Speed' do?

In the ESS Config, how do I change the direction for Pins 2 through 9 on ports 2 and 3?

In the ESS Config, what does the 'Controller Frequency' do?

In the ESS Config, what does the 'Max Step Frequency' do?

What is the difference between Step Frequency and Pulse Width?

How do I set up the Spindle?

How do I set up debounced input signals?

How do I set up Soft Limits?

My ESS has Watchdog or Ran Out of Data Messages in Mach3.

Where do I learn more about Mach3 itself?

The best place is on the Mach Support website itself!

They have a Product Manuals page that has these very useful manuals (Make sure to click onthe Mach3 tab near the top):

Mach3 Installation and Configuration Guide

Usage Guide for Mach3 Mill/Plasma

Usage Guide for Mach3 Turn

Rich's Guide to Mach3 Threading

Menu

Tangential with Mach3

Mach3 CV Notes

Mach3 Macro Programmers Reference

Mach3 VBScript Command Reference

And more!

They have a Videos & Tutorials page, with lots of videos.

And they have a support forum too.

Game Pad and/or Pendent Issues

The biggest issue with the Pendent or Game Pad is not working, is caused by not using therecommended version of Mach3.

If you jog, and the axis continues to move after you release the control, it is because Mach 3 is setto continuous mode. When in incremental jog mode, you can hold down the Shift key on thekeyboard, and then press the jog key, and it will jog continuously. Your game pad might beemulating the press of the shift key or continuous mode may have been left on.

Solutions:

Remember to press and hold the Shift key, and then hold the jog key. When you are whereyou want to be release the jog key first, and then release the Shift key. (Thank you Jeff Birt!) If you release the Shift key before you release the jog key, it will keep running until you eitherrepeat the process and release the Shift key last or you press the Reset or an E-Stop button!

In Mach3 press the Tab key and look to see if the Cont. button is yellow for Jog Mode in theMPG controller window. Press Shift to disengage it if it is stuck on with Step Mode.

Jogging Issue: It keeps jogging and doesn't want to stop

If you jog, and the axis continues to move after you release the control, it is because Mach 3 is setto continuous mode. When in incremental jog mode, you can hold down the Shift key on thekeyboard, and then press the jog key, and it will jog continuously.

Solutions:

Remember to press and hold the Shift key, and then hold the jog key. When you are whereyou want to be release the jog key first, and then release the Shift key. (Thank you Jeff Birt!) If you release the Shift key before you release the jog key, it will keep running until you eitherrepeat the process and release the Shift key last or you press the Reset or an E-Stop button!

In Mach3 press the Tab key to see the MPG Mode window. Look to see if the Cont. button isyellow for Jog Mode. If it is your Game Pad or pendant is activating it.

 

 

In Motor Tuning (and Setup), what does the 'Step Pulse' and 'Direction Pulse' field do?

Mach3's Menu -> Config -> Motor Tuning (and Setup).

The Step Pulse and Direction Pulse fields are used for a Parallel Port connection from yourcomputer to your hardware. Since you are using an external motion controller, a SmoothStepper,they are unused and may be ignored.

The Steps per Unit, Velocity (Units per Minute) and Acceleration fields are critical for tuning yourmotors. The Steps per Unit is determined by your hardware for each axis. The velocity is themaximum speed you want your axis to move. The acceleration is the maximum acceleration rateyour motors should run at (to prevent stalling or missed steps). This needs to be done for each ofyour axes.

In Port Setup and Axis Selection, what does the 'Kernel Speed' do?

Mach3's Menu -> Config -> Ports & Pins -> Port Setup and Axis Selection.

This Kernel Speed field controls the timing setting for a Parallel Port connection from yourcomputer to your hardware. Since you are using an external motion controller, a SmoothStepper,this can be ignored for the most part. Some older versions of Mach3 had internal timing issues atspeeds other than 25 kHz. So it is best to just leave it at 25 kHz all the time when connected to aSmoothStepper.

The Port #1 and Port #2 fields are also only for Parallel Port connections, and you should ignorethem when using the SmoothStepper.

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In the ESS Config, how do I change the direction for Pins 2 through 9 on ports 2 and3??

Mach3's Menu -> Plugin Control -> ESS-v***** Config

On Port 2 and on Port 3, Pins 2 though 9 may be assigned as group to be inputs or outputs.

In ESS Config, what does the 'Controller Frequency' Frequency' do?

Mach3's Menu -> Plugin Control -> ESS-v***** Config

The ESS has a fixed amount of memory, and the controller frequency is a setting for how manymotion positions per second there are, or how many times each second the velocity is sent fromMach 3 to the ESS. Having it output data faster means that if can buffer less data. If your systemis running out of data, try slowing this down to a slower frequency so the SmoothStepper can gofor longer periods of times between updates from the PC/Mach3.

4 kHz gives a buffer of 250 ms or 1/4 second: This provides a faster response to commandslike feed hold, since it uses only a quarter second buffer. However, your PC needs to be ableto supply the data transmissions to the SmoothStepper fast enough (newer PCs that are notlow end, and that are running properly, can handle this). While this provides for a snappierresponse, it will not be reliable for all machines and you may experience run out of data errors.

2 kHz gives a buffer of 500 ms or 1/2 seconds.

1 kHz gives a buffer of 1000 ms or 1 seconds: This is the default value most machinesshould use.

500 Hz gives a buffer of 2000 ms or 2 seconds.

250 Hz gives a buffer of 4000 ms or 4 seconds: Slow PCs can run this speed, and with a 4second data buffer, it will make it hard for them to run out of data. This setting will have theslowest change in velocities out of all the settings, but should still work just fine for mostapplications.

Most systems run well at 1 kHz for the Controller Frequency and that is what we recommend youset your system up with. Once you have it running well you can try 2 kHz if you want a little less

delay when using FRO or Feed Hold. At 2 kHz you will have twice as many points per second, butwith the same amount of memory the buffer will be half as long in seconds. At 4 kHz the buffer isso short that you could run out of data in the middle of a move. Windows isn't all that reliable, andso the plugin doesn't always communicate on a timely basis.

In ESS Config, what does the 'Max Step Frequency' do?

Mach3's Menu -> Plugin Control -> ESS-v***** Config

The Max Step Frequency allows you to control the frequency of the generated pulses for aparticular axis. The next image shows you how to calculate the MINIMUM Steps per Second foryour particular axis (we recommend derating it by 15% as shown in our table). Your axis willfunction properly if you set the Max Step Frequency to our recommended value.

If you use a Max Step Frequency below the minimum value recommended for your axis, it willcause that axis to not operate correctly.

Once you have your system up and running, and you are tweaking your hardware to optimize ityou may choose higher Max Step Frequencies. They may result in smoother cuts, but it willdepend on your particular hardware. As the Max Step Frequency increases, at some point it willreduces the step pulse resolution for that axis and may cause poorer cut quality and undesiredmovement quality for that axis. So use the recommended values to start with.

You will find your Steps/Unit and Units/Minute values in the Motor Tuning page: Menu -> Config ->Motor Tuning.

To calculate the Max Step Frequency setting for yourself, you can download the Excelspreadsheet.

What is the difference between Step Frequency and Pulse Width?

Step frequency is not the same same thing as pulse width; lets use some easy numbers for math:

You have a 1 kHz pulse frequency, which means you have 1000 pulse occurring per second, orone every ms

If the pulse had a 50% duty cycle (on half the time off half the time) it would be on for 0.5ms or500 us for its pulse width.

If the pulse had a 1% duty cycle, it would have a pulse with of 10 us and then be off for 990 us.

If the pulse had a 90% duty cycle, it would have a pulse with of 900 us and then be off for100us.

Step frequency is how often the pulses are being generated. Pulse Width is how long each pulse ison before it turns off to await for the next pulse to be generated.

How do I set up the Spindle?

First go to Mach3's Menu -> Config -> Ports & Pins -> Motor Outputs tab. For the Spindle row:

Place a green check for Enabled.

If you are using PWM mode for your spindle assign the Step Pin and Step Port to match yourwiring.

If you are using Step and Dir mode for your spindle assign the Step Pin and Step Port and thenthe Dir pin and the Dir port to match your wiring.

Next go to Mach3's Menu -> Config -> Ports & Pins -> Spindle Setup.

Check 'Use Spindle Motor Output'

Setup the 'Relay Control' region if you are using an output to trigger a relay.

The other settings are for a Parallel Port not a SmoothStepper.

Now go to Mach3's Menu -> Plugin Control -> ESS-v***** Config.

For a PWM Spindle

Check PWM

Set the Base Hz

For a Step and Direction Spindle

Check Step and Dir

Choose a Pulse Width, for this example I will use 4 us.

Set the 'Max Step Frequency'

Now go to Mach3's Menu -> Config -> Motor Tuning. Under Axis Selection, click on Spindle.

For a PWM Spindle

Set 'Steps Per Unit' to 1000 (This field shouldn't matter for PWM, we just need a reasonablevalue in here).

Set 'Velocity' to 60.

Set Acceleration to a value greater than '1' that gives the response you desire (depending onyour system, perhaps 200).

For a Step and Direction Spindle

Set 'Steps Per Unit' to the Max Step Frequency which is what we will assigned in theSmoothStepper Config in the last step. The max frequency will give you your max spindlespeed.

Set 'Velocity' to 60.

Set Acceleration to a value greater than '1' that gives the response you desire (depending onyour system, perhaps 200).

Click on 'SAVE AXIS SETTINGS'.

Finally go to Mach3's Menu -> Config -> Spindle Pulleys

Choose a pulley

Choose a min and max RPM so that the spindle feedback can calculate the correct RPM fordisplay.

How do I set up debounced input signals?

Go to Mach3's Menu -> Plugin Control -> ESS-v***** Config.

Enter values in microseconds (us) that a signal has to be stable for before it has been consideredchanged. This is very useful in situations where there is a lot of noise that can corrupt signals (likea plasma system), especially for things like limit or home switches, probe signals, EStop, etc...

How do I set up Soft Limits?

Soft limits are limits you set on axis travel inside the Mach3 software. They rely upon the currentvalue of the DROs (in Machine Coordinates) to determine whether the G-Code or Joggingcommands should be allowed.

To configure Soft Limits, go to Mach3's Menu -> Config -> Homing/Limits.

All values will be in the same units the rest of your system is set with (mm or inches). Make surethat a slaved axis the same settings as the master axis it is paired with.

Reversed should be checked if your axis is reversed.

Set the Soft Max and Soft Min position for each of your axes.

Slow Zone is small zone just before your Soft Limit (max or min), where the jogging commandwill slow down, so you can approach your limit without blowing past it.

Home Offset is self explanatory.

Home Negative is self explanatory.

Auto Zero is normally checked.

Speed is normally set to 20% but you can modify it if needed.

As you are approaching the limits, the jogging commands will slow you down and keep you justshort of the limit.

A GCode command will stop at the limit and issue a "Soft Limit Exceeded" message from Mach3.

For instance a command of "F200 G1 Y500" (entered in the MDI window's Input line) will stop at401 with the settings shown above. Why? Well the F2000 is the feed rate command saying tomove with a velocity of 2000 mm/s. The G1 command says to do a linear move to Y500 whichwould mean position 500 mm on the Y axis. Your DROs (and machine) should start to move. Youwould think it would stop at 405 mm since that is the Y axis soft limit, but instead it stops at 401mm, why? Well, that is because I left off the fact that the A axis is slaved to the Y axis :-) When 2axes are slaved together, Mach3 will limit you to the smallest limit of those two axes.

In order for Soft Limits to work, you must also have the Soft Limits button checked on the(Program) main screen of Mach3 (it will have a green border when active).

My ESS has Watchdog or Ran Out of Data Messages in Mach3

If you are getting Watchdog messages, that means that your PC was not able to communicate withyour ESS in the required amount of time. Go to Mach3's Menu -> Plugin Control -> ESS-v*****Config. If your Watchdog value is less than 2.0 seconds, we would strongly recommendincreasing it to at least 2.0. If it is already at 2.0, you can make it longer, but it is indicative that youhave other problems.

The first thing to do is make sure that your Controller Frequency is set to a reasonable value, andthat would typically be 1 kHz but possibly 2 kHz or 500 Hz.

When trying to solve Watchdog messages, it is common to change your settings to a point whereyou start getting "Ran out of Data" messages too. At this point. if you are getting "Ran out of Data"messages, that means your ESS is using up data faster than the PC is sending it to it.

The next step would be to adjust the Look Ahead value. Go to Mach3's Menu -> Config -> GeneralConfig... The Look Ahead value is normally 20 lines of code. Try increasing this to 100 or 200lines of code.

If you are still running out of data, we need to address PC issues:

1. Make sure your GCode that you are running, is on your PC's hard drive. It should not be ranfrom a network location, USB flash drive, external hard drive, or CD/DVD. These other datasources can have significant lag times or go to sleep, whic can cause a job to fail!

2. Make sure your computer is disconnected from the internet (it prevents programs fromupdating).

3. Don't surf the net while running Mach3.

4. Don't play music or videos while running Mach3.

5. Don't switch screens in Mach3 while running a job (this can sometimes cause enough lag todrop the connection).

6. Make sure you are not running other applications that can hog processor or hard drive timewhen running Mach3.

7. Make sure that you have restarted your PC recently (if it has been a few days, it is probablytime to restart).

8. Make sure your computer is not trying to do a Windows Update (Set it to notify you when anupdate is available for download).

9. Make sure your PC is not trying to automatically defrag your hard drives.

10. Make sure your PC is not trying to automatically scan for viruses.

11. Make sure your network adapter is not allowed to go to sleep.

12. Make sure your hard drives are not allowed to go to sleep.

13. Make sure your PC is not allowed to go to sleep.

14. Make sure your monitors are not allowed to go to sleep.

Now here are some actions you should take:

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1. Run your PC's Disk cleanup utility. It can sometimes remove GBs of useless information fromyour hard drive.

2. CCleaner is a free for personal use utility which will clean out temporary files and folders andalso clean up your registry (help with startup time (a bit).

3. Defrag your hard drive(s) if you have not done that recently.

4. Uninstall the Apple and Adobe update utilities, if they exist. They can peg out your processorlong enough to disrupt the ESS.

5. If you have 4GB of RAM or less, it would probably help significantly to get that up to 6 or 8 GBof RAM.

6. If your hard drive is almost full, adding in another hard drive for data, or upgrading it to a SSDdrive may help. Regular rotating hard drives work just fine (as long as they are not full). However, the SSD makes boot times and load times so much faster, that I only run SSDs onmy computers now (Andy).

7. Go into power options and make sure the processor is set to stay at 100%. A few PCs evenhave an additional 'Intel SpeedStep' setting in BIOS.