Index

1. The operation of the machine

1.1 Software setup
1.1.1 Mach3 driver
1.1.2 Interface of mach3
1.1.3 how to use xml file
1.1.4 pin config of mach3
1.2 Instruction of mach3
1.2.1 The Mach3 interface screen
1.2.2 MDI screen
1.2.3 X, Y, Z axis motor Tuning interface
1.2.4 Tool path Display interface
1.2.5 Mach3 Diagnostics
1.2.6 home the machine

2. Electrical Diagrams
2.1 Electrical schematic
2.2 Electrical parts list
2.3 Electrical parts instruction
2.3.1 Five axis interface board instruction
2.3.2 Spindle control board instruction

3. Troubleshooting
3.1 Overview
3.1.1 Attention
3.1.2 Troubleshooting overview
3.2 Troubleshooting
3.2.1 Power distribution
3.2.2 Computer control
3.2.3 Axis driver
3.2.4 Spindle driver

1 www.syil.com
1. Operation of the machine
1.1 Software setup
If you don’t have a copy of mach3 first download a copy at

http://www.machsupport.com/downloads.php,

make sure to download the newest version * Lockdown: * Mach3 R2.63.

After downloading and installing the software it is vital to reboot the computer as the
installer will prompt. Do not start up mach3 without this vital reboot, if you do not
do this you will have to manually remove mach3 from your system and reinstall. It
is best to install mach3 in to the default directory , C drive as this can make things
easier for trouble shooting.

Figure 1-1
After install you may see this screen as Figure 3-1, if you don’t see this screen, don’t
worry about it.
Printer port operation will be set as then click OK and Don’t ask me this again.

2 www.syil.com
1.1.1 Mach3 driver

Figure 1-2
After you have completed the installation of mach3，see mach3 driver 'MACH3
DRIVER' in device manager(as Figure 1-2)，or the machine will be out of control.

To check to see if the drive installed properly you then can confirm this by, “C drive”,
“mach3”, look down the list until you see:

By opening this software Mach3 will do a test on the driver, if this fails you must
reinstall Mach3 or use In the same directory.

3 www.syil.com
1.1.2 Interface of mach3
After you start the software ,the interface of mach3 is as Figure 1-3

Figure 1-3
Attention: Before you attempt to control the machine with mach3,the button of
RESET must be inactive.

1.1.3 how to use xml file

Your syil distributor should have provided you with a syil .XML file, this file is a
setup file for mach3. This file will make your installation plug and play. locate
this .xml file and copy it by right clicking and select COPY. Open “MY COMPUTER”
select the ``C DRIVE``, `mach3``. Paste this .xml file in to a open place in the
directory, do not paste in to any internal mach3 folders.

MACH3 LOADER

Open the mach3 loader and select the x5 profile(as Figure 1-4)

4 www.syil.com
 Figure 1-4
1.1.4 pin config of mach3
After get into the mach3 interface, please check the pin config, make sure they
are right, the pin of x5 is as Figure 1-5

Signal name pin I/O of the Signal

X pulse 7 output
X dir 17 output
Y pulse 6 output
Y dir 8 output
Z pulse 5 output
Z dir 16 output
A pulse 4 output
A dir 14 output
Spindle pulse 2 output
Spindle dir 1 output
Signal 1 3 output
Signal 2 9 output
X home 12 input
Y home 13 input
Z home 10 input
A home 15 input
E-stop 11 input
Figure 1-5
The information should all ready be pre set in the (x5).xml file

5 www.syil.com
1.2 Instruction of mach3

1.2.1 The Mach3 interface screen

1: Mach3 Gcode window, user this will display the current active gcode program, the
white bars shows the line that is currently active.

2: (DRO) this digital read out shows the current location of each axis, in either work
piece coordinates or machine coordinates
3: this will display the tool cutting path, this window can be very useful. If your
program is loaded you should see the similar part. (if you do not you might not want
to push the start button).
The mouse can be used to change the perspective.

4: interface procedures:
Cycle start: To run current loaded program
Feed hold: program suspended
Stop: stop program (do not use as estop) in emergency use ESTOP
Edit G-code: Edit current program
Recent file: the recent run-off procedures document
Close G-code: Close the program

6 www.syil.com
Load G-code: loading program files
Set next line: a set of enforcement procedures
Line: is currently running a number of
Run from here: from the current line running show that in the white bar
Rewind: re-start procedures
Single BLK: a single operation (this will advance 1 line each time cycle start button
is pushed)
Reverse run: repeat run
Block delete: delete breakpoint
M1 optional stop: to stop the use of M1 code
Flood: turn on coolant

5: Tool information:
This information is crucial to proper tool changes and setting up tools in the tool table.
The tool displayed is the tool that is currently active, as well as the current height
offsets.

6: Feed interface:
FRO: this displays the current programmed feed. This number can be manually
changed only if a M48 is used in your starting lines of code.

7: spindle speed control interface:

Spindle F5 CW: this butto is used to start the spindle manually.

RPM: spindle speed feedback display interface. In the absence of spindle speed
feedback, which will appear as 0.
S-ov: Theory should reach spindle speed, RPM and that can be compared.
Spindle speed: spindle speed manual adjustment interface.
You can also manually enter the spindle speed.

8: Mach3 Tabs.
Program run: Comprehensive program control interface.
MDI: manual data Input.
Toolpath: tool path control interface.
Offsets; used to set up work piece cords (g54) and tool length offsets .
Settings: Alter mach3 settings
Diagnostic: Used to diagnose mach in case of problems.

7 www.syil.com
 1.2.2 MDI screen

MDI (manual data input)

This screen is very helpful, simply type in the a code command in to the white line this
allow for quick and easy manoeuvrability. (eg) to move all axis to work piece home
just type in (g00 x0y0z0) or to send machine to home position type in (G28)

This is a complete list of MACH3 gcodes

8 www.syil.com
This a complete list of mach3 M codes

1.2.3 X, Y, Z axis motor Tuning interface

9 www.syil.com
 -

This is the X, Y, Z axis adjust the speed of the interface, located in the motor tuning
config settings,
1: Pulse settings,
this drives the need to set for the syil products, the default setting is for 400 metric
and 10160 for imperial. These numbers are imperative to the proper operation of
your machine.
2: velocity,
This directly controls the inches or mm per min, in your rapid movements (G00)
If you tune this to quickly this can result in lost steps and damage to your work piece
and can result in a major crash. Contact your distributor prior to changing this setting.
3: Acceleration adjustment:
This setting controls how fast the stepper motor get to the designated Velocity, again
too fast and this can result in lost steps.

4: Switch-axis:
This allows you select each individual axis to tune, you must select save axis in order
to use the changed parameters. This must be done on each axis.

NOTE: Motor tuning is like tuning a guitar, it is a perfect balance between, steps,
velocity, and acceleration. If you do not know what you are doing, we do not suggest
altering these setting without contacting a dealer.

10 www.syil.com
 1.2.4 Tool path Display interface

This is the tool path observation interface, integrated interface corresponding to

1,2,3,4.
This screen is larger and can aid in observation of the current program, also the
simulate program is helpful as I can give a estimated program run time.

11 www.syil.com
1.2.5 Mach3 Diagnostics

Digonstic interface,

This screen is very useful in knowing what your machine is doing, this is extremely
helpful in case you are having issues with the machine. This screen is set up to allow
you to still run your program and see exactly what you machine is doing.

1: Displays current gcode program.

2: Shows input and out put signals from your machine and computer.
3: MDI (manual data input) line allows for manual input of gcode.

This screen can be very useful to check communication between the machine and the
computer, simply depress one of the x or y homing switches and you will see the
corresponding light illuminate.

12 www.syil.com
 1.2.6 home the machine

Homing the machine is when you send the X,Y and Z to the homing switches, this
crucial the producing precise parts and components. The machine knows is
positioning in space due to mathematical calculations, on how far away it is from its
homing switch. It is extremely important to home the machine every time you power
up the machine, and or the computer.

This is achieved by going to the main mach3 screen set,

#1 push the machine crord’s button, you will know it is active when the light around
it is red.

#2 then push the “REF ALL HOME” button.

This will send all axis home to the switches, for this function to work properly you
must have the auto Zero set under ‘config’, - homing and limits.

NOTE: it is always best to make sure that your tool is completely clear of the work
piece prior to homing the machine.

13 www.syil.com
You can change the direction of axis and home axis in the following screen:

14 www.syil.com
 KM1 5 Axis interface
board
X-Home
Y-Home
Z-Home
·Schematic for x5

Estop
Contacts Contacts
2.1 Electricity schematic
2. Electricity instruction

15
VFD-M

Step Motor Driver Step Motor Driver Step Motor Driver Step Motor Driver

Spindle motor Coolant motor

www.syil.com
2.2 Electricity parts list
·Parts list for x5
NO. parts Num Remark
1 VFD-M 1
2 1100W AC motor 1
3 220v Transformer 1 40v output，24v output，
12v output, TC
4 5 axis interface board 1
5 step motor driver 3
6 step motor 2 For X axis and Y axis
7 750w servo motor with 1 For Z axis
brake
8 Leakage circuit breaker 1 QF0
9 home/limit switch 3 X-home, Y-home, Z-home
10 plug 1
11 power wire 1
12 Trunking Use 3m
13 switch 1
14 Switch for 4 axis
th 1
15 24V A.C Contactor 2 KM1,KM2
16 24vdc relay 1 KA0

2.3 Circuit board reference

16 www.syil.com
 2.3.1 Five axis interface board
This board is for x5 series

1：12VAC/VDC power input

2：Spindle control port
3：0~10v output signal
4：X-ref( +5V,S,GND)
5：Y-ref( +5V,S,GND)
6：Z-ref( +5V,S,GND)
7：A-ref( +5V,S,GND)
8：E-stop port(S,GND)
9：Connect to parallel port
10：Jumper: use pin 1、2, open charge pump; use pin 2、3: close charge pump
11：Port for X,Y,Z,A,B step motor driver
12: Relay for coolant pump

2.3.2 Spindle control board

2.3.2.1 Interview

17 www.syil.com
1, the product must be installation, commissioning, operation and maintenance by
professional and technical person. the product is electrical equipment, incorrect
using or wiring will cause electrical shock, fire, explosion or other dangerous!

2.3.2.2 Spindle driver

Model Parameter
Voltage 220V
Power 1.5KW

You can get more detail from VFD-M manual.

2.3.2.3 Motor Features

Model Parameter
Type MAV3 80-4
Frequency 50hz
Output 1.5HP, 1.1KW
Poles 4
Voltage 220v/380v
AMP 1.1A
Max Frequency 200HZ

18 www.syil.com
 RPM 1450
Weight 13.5kg
P.F. 65%

2.3.2.4 mounting dimensions

2.3.5 4th Axis instruction

The 4th axis is Optional Accessories, and it’s for x5 series

19 www.syil.com
 The rotary table are mainly accessories for milling machine, boring machine and
drilling machine, they can be used for listing things:
1. circular cutting, the table in graduated with a 360°scale
2. angle setting
3. boring
4. spot facing operations
5. similar work in conjunction with a milling machine
6. indexing
7. in a vertical position to enable to carry out center work with the help of tailstock
8. the dividing plate accessory allows the operator to accurately divide the 360°
rotation of the clamping surface into divisions of all divisible of 30＇

Specifications:
Diameter of rotary table: ￠100 mm
Height of center for horizontal mounting: 73 mm
Taper of center bore: MT#2
Width: 8mm
Width of locating key: 8mm and 10mm
Angle of T-slot: 90°
Height of center for ver.Mounting: 68mm
Driving ratio of worm gear: 1:72
Module of worm gear: 1
Graduation on table circumference: 360°
Max feedrate: 600mm/min

3. Troubleshooting

20 www.syil.com
3.1 Overview
This section is very important, if your machine has issues.

3.1.1 Attention
Our machine is an intergration of mechanical components, Digital components,
electrical components, personal computer and software.
The following are some events which may cause the machine not work correctly.
·The machine was transported, and wiring may have come loose
·There was a thunderstorm w/ lightning since the machine was last used and now
the electronics do not work.
·There has been water in the area where the machine is located
·The machine is in unheated outside building.

3.1.2 Troubleshooting overview

Tools for troubleshooting

Frequently problems

yes
Do you need
schematic?
Refer to schematic (3.2)

no
no
If the
problem

Refer to troubleshooting
yes

yes
If the
Well done
problem

no

Call syil support

Figure 3-1
This is the troubleshooting overview, as Figure 3-1,you can try to solve the problem
as above, the next will instruct the all process detailed.
Attention for troubleshooting:
·Have knowledge of how machine is supposed to work.

21 www.syil.com
 ·Divide and conquer—focus on one area
·Analyze what has changed
·Work smart—do the easy and obvious tests first
·Complete one test before starting another.

3.1.2.1 Tools for troubleshooting

3.1.2.1.1 Safety
· Never do anything with machine power on that can be done with
machine power off.
·Wear eye protection and use appropriate protective clothing such as
gloves
·Don’t wear loose clothing
·Don’t wear jewelry as this can contact electrical componants.
·Do not do any electrical testing if the floor is wet.
·Do not plug machine in to receptacle if floor is wet.
·Be very cautious on which electrical components your are going to touch, as capacitors
can hold a charge even with the machine powered off.
·Think about each move you are going to make prior to doing so, and if
you are unsure do not proceed.
·Focus on the specific task, as working on electrical components can be
very dangerous.

3.1.2.1.2 Tools for troubleshooting

·Good lighting (trouble light or a headlamp or flashlight)
·A digital multi-meter that can test AC volts, DC volts and resistance.
·Assorted non magnetic rubberized screwdrivers.
·A wire stripper
·Measuring tools: Tape measure, Calipers, Dial Indicator(Optional).

3.1.2.1.3 Frequently problems

There are several problems frequiently, if your machine has issues, you can try to
solve the problem by doing the following.

·Loose wires:
There are many wiring connections, it only takes one loose connection to cause
the whole machine to fail. Syil has ensured the wiring connections are tight at the
factory, but when the machine is shipped to you ,the connection may come loose.
The first thing to always check is the wiring connections, tighten all harnesses.

·Poor cable connections:

As the same reasons for above, the cable also may become broken or loose, if

22 www.syil.com
 the machine cannot function normally, please check all cables(include all the
cables inside of the control box and the parallel port cable), if you find that a
wiering harness is broken contact your local regional dealer or [email protected]

·Software and parallel port problem:

It is best to, restart software or reinstall mach3, the problem may be solved ,if
you change any setting in mach3 ,this may also cause a mach3 error.
If mach3 works and the machine works but there is still no communication to
the machine, You should check your computers parallel port. It is possible for the
personal computer port to be broken ,there is two ways to solved the problem:
1.Change the mother board of your computer or change another computer and
test again.
2.Purchase a PCI-Parallel board and install it on the PCI port of your
motherboard. Be aware that the port address will change, you will need to
change this address in the (ports and pins) settings in mach3.

SYIL DOES NOT ADVISE USING A LAPTOP COMPUTER TO RUN MACH3, AS

LAPTOP COMPUTERS PARELLEL PORTS CAN HAVE ISSUES WITH KEEPING THE
PROPER 5V SIGNAL REQUIRED. You will see the same warning on the mach3 web
site.

·Sensors
The homing sensors are install on each axis, these switches are used for
homing the machine, if the sensors is broken, the machine will loose the homing
function. To Test go to the diagnostic screen in mach3, depress the switch on
the x or y axis. You will see the lights light up.

23 www.syil.com
 These are not limit switches and by default will not stop you machine from going
past them. Mach3 has a function called (soft limits) this function can be turned
on from the main screen for mach3 and set up in the homing/limits settings.
This is found under the “Config” menu in mach3. For more reference please
check the

mach3 manual, this can be found @

http://www.machsupport.com/documentation.php

This is also a good way to test the communication to the computer.

·Computer
The recommended configuration of computer: CPU is 1GHZ, EMS memory is
256MB, hard disk space is 150MB,if the computer is old, mach3 may not will run.

·unlicensed software
When you run program in mach3,the program may limited in 999 lines,
because yours is demo version, you will need to buy the license, and there will
no line limiting.

·Unexplained stop
This may be caused by electrical noise, this can be caused by the homing

24 www.syil.com
 switch, it is important to use good quality shielded cables.

3.1.2.1.4 Syil support

[email protected]
[email protected]
0086-574-62735995
You can send email for troubleshooting in anytime, or call us in work time, the
work time is 8:00-17:00(GMT+08:00),prior to contacting us ,be sure you have the
following information.
·Serial number of your machine.(Located on the top of column)
·If you have found a problem the machine, and may need to replace some parts
from Syil, we will need to know the date of purchase you, the syil Machines carry
a One-year warranty. If the warranty has expired you will need to purchase
new components.
·Analyze what might have changed since the machine worked properly.
·Make sure you can repeat the problems.
·Describe the problem as detailed as possible, it will help us to diagnose what will
need to be fixed.

3.2 Troubleshooting

25 www.syil.com
 Start

no
Is there any Proceed to the
power? Power distribution

yes

no
Is software Proceed to the
work ok? Computer control

yes

no
Does Axis Proceed to the Axis
work ok? driver

yes

no
Is spindle Proceed to the
ok? Spindle driver

yes

end

Figure 3-2
The flowchart in figure 9.18 will guide you where to start troubleshooting the
electrical system.

26 www.syil.com
 This is the power switch, when it
switch to “0”,the power is disconnect,
and when the switch is on “1”, the
machine will get power supply.(as
Figure 3-3)
Most problem of the power supply is
caused by the switch.
The following is power distribution
check list:
Figure 3-3
3.2.1 Power distribution
parts Input power Output power Remark
Power supply 220vac(110vac) 5vdc:supplies power to
(x5 plus only) the x5 plus control board

Transformer 220vac(110vac) 40vac:Supplies power to

(x5 series) the stepper motor driver
24vac:supplies power to
the A.C.contactor
12vac:supplies power to
the interface board
Power supply 220vac(110vac) 12vdc:supplies power to
(x5 speed the x5 plus control board
master only)

3.2.1.2 Problem resolution checklist for power distribution

Problem Action to How to solve Remark

identify cause of
problem
·After turning 1. Check the 1. make sure the
on the power, power plug.. connection is good. If
there is no the power plug have any
power in problems, replace it
circuit immediately.

27 www.syil.com
 2.Check the 2.if the switch is broken
switch. replace the switch. This
can be confirmed via
volt meter

·Loose wires 1.Remove 1. Find loose wires, and

in circuit power from re insert.
machine ,than
check ALL
connections
wires.
The boards 1. the spindle 1.Check the fuse or filter,
have no control board if the board is broken,
power. has no power . replace it.

2.the five axis 2.check the fuse on the

board in no board or the power
power. supply to the board,. if
the board is broken,
replace it.
Coolant pump 1.Check the 1.if the plug is
is no power power plug.. loose ,tight it.
supply
2. Check the 2.If the relay is not
second relay. working, replace it.

28 www.syil.com
3.2.2 Computer control
3.2.2.1 Overview
Mach3 can work well in windows xp.

5 axis
interface
Mach3 cnc board
controller

Computer Parallel port

Parallel port cable of 25pin

Figure 3-4

3.2.2.2 Problem resolution checklist

Problem Action to identify How to solve Remark

cause of problem
The machine 1.check the 1. make sure the
can’t be parallel cable connection is good. If
controlled by between the cable has
computer computer and problems, replace it
machine. with high quality
shielded cable.

2.check the 2. If the parallel port

parallel port on the machine is
broken replace it.

Mach3 can 1. check the 1.Make sure all

works, but parallel cable connections are tight.
machine will If the parallel cable
not work. appears to have
issues, replace it.

29 www.syil.com
 2. Check that if 2. Make sure the
the mach3 mach3 driver
Driver has install installed. In the
properly. mach3 folder there is
a test program ,for
the driver
3.Make sure that 3.if suspected that
mach3 is mach3 is not working
working properly reinstall
correctly.
If the 1.check the 1.if there is no power,
machine and power for check the power
the computer interface board . supply.(as 3.3.1)
is ok, but the
machine is
still not able
to be 2. check the 2 make sure the
controled charge pump. charge pump is
working, if the
charge pump is not
working refer to 3.3.1
as the entire machine
will not work
3.if you are 3.make sure your
using a parallel address is as same as
port card, check the parallel port card.
the address of
port1

30 www.syil.com
3.2.3 Axis driver
3.2.2.1 Overview

Control
signal
X- axis x-axis driver
command

x-
Control
axis
signal
M
Y- axis y-axis driver
command

y-
Control axis
signal M
Z- axis
z-axis driver
command

z-
Control axis
signal M
A- axis a-axis driver
command

a-
axis
M

Figure 3-4

31 www.syil.com
3.2.2.2 Problem resolution checklist

Problem Action to identify How to solve Remark

cause of problem
A specific 1.check the 1. make sure the
axis can’t be parallel cable connection is good. If
controlled between the cable has issues,
by computer computer and replace it.
machine.
2.check the 2. if the parallel port
parallel port is broken replace it.

3.check mach3 3.if the software is

broken by unknown
problem, reinstall it
stepper 1. check mach3 1.check mach3, and
motor reinstall.
looses steps
2.check step 2. if stepper motor
when
motor and wiring, have having
machining.
For example, x, issues, replace it.
axis have some Do not unplug
problem, you can stepper motor
do as Figure 3-6 with machine on
and computer on.
This will cause 5
axis card to not
work
stepper 1.check the 1.if the driver is no
motor driver power supply for power, check the
is not work. driver wiring.(refer to
3.3.3 )

2. do as Figure 3- 2 .if the cable is

5 to check the broken, replace it
cable of control
signal.

32 www.syil.com
The driver 1. Check the 1. if the coupling is
and the coupling on the broken, replace it.
stepper motor.
motor are
working, but
the axis is
not moving.
axis is 1.check the 1.If the homing
limited by homing switch switch not working
limit switch replace it. Refer to
or e-stop 3.1.2.1.3 Frequently
switch problems

2.check the e- 2. if the e-stop switch

stop switch is not working
replace immediately,
do not change
settings in mach3
to disable switch!
Mechanical 1.Gibbs are too 1.Adjust Gibb set
problem tight or too loose screws

2.oil not getting 2.investigate oiling

to the ways system for lack of oil
and/or plugged lines

3.debris on 3.clean ballscrew

ballscrew.

33 www.syil.com
 Control
signal
X- axis x-axis driver
command

x-
axis
M
Y- axis Control y-axis driver
command signal

y-
Control axis
signal M
Z- axis
z-axis driver
command

z-
Control axis
signal M
A- axis a-axis driver
command

a-
axis
M

Figure 3-5

34 www.syil.com
 Control
signal
X- axis x-axis driver
command

x-
Control
axis
signal
M
Y- axis y-axis driver
command

y-
Control axis
signal M
Z- axis
z-axis driver
command

z-
Control axis
signal M
A- axis a-axis driver
command

a-
axis
M

Figure 3-6

35 www.syil.com
3.2.4 Spindle driver
3.2.4.1 Overview

220v/110v
power input

filter

VFD 5 axis
7 pin wire
Interface board

Computer
M

Figure 3-7

36 www.syil.com
3.2.4.2 Problem resolution checklist

Problem Action to How to solve Remark

identify cause of
problem
The spindle 1.check the 1. make sure the
can’t be parallel cable connection are good.
controlled by between If the cable have
computer. computer and suspected problems,
machine. replace it.

2.check the 2. if the parallel port

parallel port is broken replace it.

3.check mach3 3.if the software is

broken by unknown
problem, reinstall it

4.check the 3.if the spindle

spindle control control board is
board broken, replace it.
To test check that the
board is getting
power.
2.check the 7.if the motor is
spindle motor broken ,replace it

The spindle 1. check set of 1.Make sure the

does not pulleys in pulley is 200 to 5000
achieve mach3
programmed
RPM. 2.check motor 2.Make sure the
For example, control in PWMbase freq. is 100
use“m3s1500”, mach3
but the true
RPM is only
1000

37 www.syil.com