1. Product Overview
The HLTNC MACH3 CNC Controller Board is designed to interface with your computer and motor drive modules for controlling CNC machines such as lathes, milling machines, and routers. It supports various configurations including 4-axis USB, 5-axis DB25 LPT, and 5-axis USB.
Video: HLTNC CNC Controller Board Product Overview.
Package Contents
Please note that a physical CD is not included. Software and plugin files are available via email or the provided Google Drive links.
- For 4-Axis USB Port Board:
1 * 4 Axis USB Port CNC Breakout Board
1 * USB Cable - For 5-Axis DB25 Port Board:
1 * 5 Axis DB25 Port CNC Breakout Board
1 * DB25 LPT Cable
1 * USB Cable - For 5-Axis USB Port Board:
1 * 5 Axis USB Port CNC Breakout Board
1 * USB Cable
Image: HLTNC 4-Axis USB Mach3 Controller Board.
Image: HLTNC 5-Axis USB Mach3 Controller Board.
Image: HLTNC 5-Axis DB25 LPT Mach3 Controller Board with included cables.
2. Setup Guide
2.1 Software Installation (Mach3)
The Feidiao Series MACH3 motion control card uses a USB driverless design, ensuring good compatibility with XP, WIN7, or WIN8 (32-bit or 64-bit systems).
- Obtain Mach3 Software: Download the Mach3 software and plugin files from the provided Google Drive links:
- Run Installer: Locate and run the Mach3 installation program (e.g., "Mach3VersionR3.041安装程序.exe").
- Follow Prompts: Proceed through the installation by clicking "Next" or "Yes" as prompted. The default installation location is typically
C:\Mach3. - Important for 64-bit Systems: During the final step of installation, do NOT check the "Load Mach3 Driver" option. Checking this option on 64-bit computers may lead to an installation error.
- Finish Installation: Click "Finish" to complete the Mach3 software installation.
2.2 Localization and Plugin Setup
- Localization Files: If you wish to localize your Mach3 installation, copy the `Mach1Lic.dat` file from the localization package (e.g., "mach3 Chinese and crack.rar") to the Mach3 installation folder, overwriting the original file. Ensure all files are copied completely to avoid localization issues.
- Copy Plugin and Profile:
- Copy the provided `Mach3Mill.xml` configuration file to your Mach3 installation folder, replacing any existing file. This will save significant configuration time.
- Copy the entire `Plugins` folder from the provided files to your Mach3 installation folder. Motion control cards require corresponding plugin support to function correctly with Mach3.
2.3 Hardware Connection
The control card connects to your computer via a USB cable and to the motor drive modules via signal cables. Refer to the wiring diagrams below and the terminal instructions for your specific motor drive and other equipment.
- Connect USB: Connect one end of the USB cable to your computer and the other end to the control card.
- System Recognition: Allow the operating system to automatically recognize the control card. Once recognized, the blue indicator light on the control card will illuminate, confirming proper connection.
- Connect Motor Drives: Connect the control card to your motor drive modules.
WARNING: The control card has two physically isolated rows of terminals. When wiring, ensure that the two sets of signal lines on these terminals are NOT connected to each other. Incorrect connections can cause external interference, affecting system stability and potentially damaging components.
Typical Wiring Examples:
Image: Connection Diagram for 4-Axis USB Controller Board, showing connections for spindle converter, sensors, power supply, 4-axis controller, MPG handwheel, and USB connection.
Image: Connection Diagram for 5-Axis DB25 LPT Controller Board, showing connections for spindle converter, sensors, power supply, 5-axis controller, and USB connection.
Motor Drive Connection Methods (X-axis example):
There are two main connection methods for motor drive modules:
- Common Cathode Connection:
XP -------- PUL+
GND ------- PUL-
XD -------- DIR+
GND ------- DIR- - Common Anode Connection: (Requires level configuration modification in Mach3 for normal motor rotation)
XP -------- PUL-
5V -------- PUL+
XD -------- DIR-
5V -------- DIR+
3. Operating Instructions
3.1 Initial Startup and Emergency Stop Reset
When Mach3 starts, it is in an emergency stop state for safety. Neither manual control nor G-code can be executed until this is released.
- Start Mach3: Launch the Mach3 software.
- Release Emergency Stop: Press the 'Emergency Stop Reset' button within the Mach3 interface. The machine will only begin moving once this button stops flashing.
Image: Location of the Emergency Reset button in Mach3.
3.2 Manual Operation (Jogging)
You can manually move the machine using the keyboard controls.
- Access MPG Mode: In the Mach3 interface, press the
TABkey on your keyboard to bring up the manual operation handle (MPG mode). - Move Axes: Use the control keys to move the machine along each axis.
- Adjust Speed: The speed of point-and-move operations can be adjusted using the "slow point-and-move rate" setting.
- Continuous vs. Step Mode:
- Continuous Mode: Pressing a control key moves the machine tool continuously; releasing it stops the movement.
- Step Mode: Each press of a control key moves the machine tool by a specified distance (e.g., 0.1 millimeters per press in "point cycle mode").
3.3 Running G-code
- Load G-code: In the Mach3 menu, select "File" > "Load G code". A dialog box will appear.
- Select File Type: If you don't see your G-code file, change the file type to "*.ncc".
- Start Operation: After loading the G-code, press the "Cycle Start" key to begin the operation.
- Pause/Resume: Press 'Pause' to temporarily stop the machine. You can manually move the machine while paused. Press 'Cycle Start' again to resume operation from where it left off.
- Interrupt Operation: Pressing 'Stop' or 'Emergency Reset' buttons will interrupt the G-code operation.
- Restart Process: After an operation ends, press 'Return to Start' to restart the process.
- Manual Coordinate Input: The coordinate display box in Mach3 allows manual input of coordinates. To set coordinates to (0,0,0), click on the coordinate display box, enter '0', and press 'Enter'. The color of the box will change slightly to indicate it's active.
3.4 Parameter Setting
Motor parameters in Mach3 must be configured according to your machine tool's specifications.
- Access Motor Tuning: Execute the menu "Setting" > "Motor debugging".
- Steps Per Unit: The first parameter to set is the number of pulses required for each unit (mm) of movement. The calculation formula is:
Steps Per = (360 / step motor per step degree) * subdivision factor / screw lead
For example, for a stepper motor with 1.8 degrees per step, 16x subdivision, and a 5mm screw lead:Steps Per = (360 / 1.8) * 16 / 5 = 640 - Maximum Rate: This is the moving rate of the G0 statement. The calculation is:
Maximum rate = 60 * 100K / (Steps Per)
Note that this is a theoretical maximum. The actual achievable speed should be reduced (e.g., to about 40% of this theoretical speed) due to stepper motor torque decay at higher speeds. - Acceleration: This parameter is typically set between 100 and 1000. Experiment to find the appropriate acceleration for your machine. High acceleration can cause intermittent movement, while low acceleration increases processing time and reduces quality.
- Save Settings: After setting parameters for each axis (X, Y, Z, A), remember to press the "Save" key for each axis individually.
4. Specifications
4-Axis USB Controller Board
- Axis Support: 4-axis linkage (connects four stepper motor drives or servo drives).
- Pulse Frequency: Maximum step-pulse frequency is 100KHz.
- Features: Supports automatic probe tool, emergency input, limit switch, electronic handwheel.
- Power Supply: Requires external 24V DC power supply for USB and external port isolation and system stability.
- Spindle Control: 0-10V output port for Mach3 software control of spindle motor speed.
- Inputs: 4 general-purpose inputs (for limit switch, E-stop switch, probe switch, back to zero, etc.).
- Outputs: 4 general-purpose isolated relay drive output interfaces (controls four relays for spindle start, forward/reverse rotation, pumps, etc.).
- Status Indicator: 1 status LED to indicate connection status.
- Dimensions: 8x7.7cm (3.15x3.03 inches).
5-Axis DB25 LPT Controller Board
- Software Support: Full support for MACH3 and other computer software supporting parallel port control.
- Power Isolation: USB power supply and peripheral power supply are separated to ensure computer security.
- External Power: External wide voltage input, 12-24V, with anti-reverse connection function.
- Input Isolation: All input signals are isolated by optical fiber (for emergency stop, tool setting, limit, etc.) to ensure computer safety.
- Relay Output: One relay output port (P17) to control the spindle switch.
- Analog Output: A 0-10V analog voltage output isolated by optocoupler (P1) to control inverters with corresponding analog interfaces and spindle speed.
- Axis Control: All 17 ports are open, can be connected to drivers with optocouplers, capable of controlling a 5-axis stepper motor.
- PWM Output: P1 is used as PWM output, which can control spindle governors with optocoupler input.
- Driver Compatibility: Can be connected to common negative or common positive drivers; input level is 5V driver.
5-Axis USB Controller Board
- Axis Support: 5-axis linkage (connects five stepper motor drives or servo drives).
- Pulse Frequency: Maximum step-pulse frequency is 100KHz.
- Features: Supports automatic probe tool, emergency input, limit switch, electronic handwheel.
- Power Supply: Requires external 24V DC power supply for USB and external port isolation and system stability.
- Spindle Control: 0-10V output port for Mach3 software control of spindle motor speed.
- Inputs: General-purpose inputs (for limit switch, E-stop switch, probe switch, back to zero, etc.).
- Outputs: Isolated relay drive output interfaces (controls relays for spindle start, forward/reverse rotation, pumps, etc.).
- Status Indicator: 1 status LED to indicate connection status.
Image: Dimensions for 4-Axis USB (left) and 5-Axis DB25 (right) Mach3 Controller Boards.
5. Troubleshooting
- "RnRMotion Controller Configuration" Dialog Not Appearing:
If the configuration dialog does not appear after executing the "RnRMotion Control Card" menu item, ensure the control card is properly connected to the computer. This issue can also occur on older operating systems like Windows XP, especially if system optimization software has been run. - 64-bit Driver Installation Error:
When installing Mach3 on a 64-bit computer, make sure to NOT check the "Load Mach3 Driver" option during the final installation step. This is a common cause of installation errors. - Mach3 Localization Issues:
If you experience problems with Mach3 localization, ensure that all localization files (e.g., `Mach1Lic.dat`) were copied completely to the Mach3 installation folder and overwritten existing files as prompted. - Motor Rotation Not Normal (Common Anode Connection):
If using a common anode connection for your motor drives, you must modify the level configuration within Mach3. Failure to do so will result in abnormal motor rotation.
6. User Tips
- Software and Plugins: Always ensure you have the correct Mach3 software version and the corresponding plugin (`rnrmotion.dll`) installed. Check the provided Google Drive links for the latest versions.
- Connection Verification: After connecting the control board via USB, verify that the blue indicator light illuminates, confirming the system has recognized the board.
- Initial Setup: Take your time during the initial Mach3 software setup, especially when configuring motor parameters. Incorrect settings can lead to poor machine performance.
- Support: If you encounter difficulties, refer to the official user manual PDF for the Fei Diao Series Motion Control Card: Quick Start Manual (PDF). For further assistance, contact the manufacturer's support.
7. Warranty and Support
This product is CE certified. For detailed warranty information, please refer to the terms provided at the time of purchase or contact your seller. For technical support and inquiries, please reach out to HLTNC Official Store or consult the comprehensive PDF manual linked above.