Mill and Router Setup Manual

Introduction

Complete these steps in order. Steps that integrate with a specific motion controller are covered in that controller’s integration documentation.

1. Connect the motion controller and MachPro PC with a shielded network cable.
2. Connect the cables between the motion controller and the drives.
3. MachPro startup and license install.
4. Axis setup and calibration.
5. Map input signals, then set up homing (and any slave-axis homing).
6. Set soft limits, map output signals, and configure the spindle.

123

1. 1Machine status and mode indicators
2. 2Position readout (DRO)
3. 3Cycle start / feed hold controls

MachPro CNC mill control screen (2026)

Languages

You may change the display language for MachPro screen labels and buttons from Operator → Select Language. Restart MachPro after selecting a new language.

Operator -> Select Language

Danger

If your CNC training was primarily in English, configure MachPro in English, then switch to the operator’s language for daily operations.

Spindle settings

Open Configure → Control → Settings, flatten the tree, and expand the Spindle section. The most common features:

• Gear shifter — configure gear ranges, then set Max RPM per gear (M40-M45).
• Orient — MachPro uses M19; Manual mode works with defaults.
• Sub spindle — set Enabled, CW/CCW outputs, and Max RPM (M13/M104/M105).

Spindle section of the Settings tree

Global Monitoring System

Shared: Global Monitoring System (GMS)

The Global Monitoring System sets up user alerts/messages and controls I/O based on conditions. The machine watches for specified conditions and takes action when they are met. Open it via Configuration -> Plugins -> Global Monitoring System.

Global Monitoring System configuration

Monitor classes

The system can initiate four classes of action:

• Alarm — emergency conditions; can disable the machine or stop motion; requires operator intervention.
• Warning — non-critical issues; prevents Cycle Start; alerts the operator.
• Notice — informational only; takes no automatic action.
• Process — background control actions; does not alert or block Cycle Start.

Pro Tip

Use Alarm for safety-critical faults, Warning for operational issues, Notice for information, and Process for silent automation tasks.

Conditions

Conditions are organized into sets (AND / OR / NOT) and items. Most monitors only need a single AND set. Add an item by choosing a condition type, filling in the details, and pressing Add Condition.

Monitor conditions editor

Warning

Set longer rather than shorter action timings. Timings that are too short can overwhelm the computer. For quick responses, start at 500 ms and only decrease if needed.

Tool changers

Shared: Tool Changer Setup

The MachMotion plugin supports wine-rack and carousel tool changers. Both combine user-defined rack/pocket positions with a pre-programmed change sequence and built-in safety checks. The changer works with the rack parallel to X or Y.

Determine which axis the rack is parallel to

Configure the correct orientation

1. Determine which axis the rack/carousel is parallel to (X or Y).
2. Open C:\Mach\Profiles\Router\ToolTables.
3. Keep the file that matches your orientation; archive the others (optional, keeps things clean).

Set tool pocket positions

1. Carefully position a tool in each pocket holder.
2. Record the machine-coordinate (G53) position for that pocket.
3. Enter each recorded value into the corresponding tool-pocket field.

Important

Set each pocket position individually. Do not copy values between pockets — even small physical differences can cause broken tool forks.

Pro Tip

Don’t set these up with a tool in the spindle. It is more accurate to put a tool in the fork, open the drawbar, and jog the spindle onto the tool while watching the gap between the tool taper and the spindle taper.

Tool pocket positions (set each individually)

After entering positions you must save the document so the CSV conversion macro runs; otherwise the changed positions have no effect.

Enable the tool changer: Predefined Filters -> Tool Change

Drawbar signal mapping example

Pro Tip

All tool changes happen at Rapid. Before testing your first change, lower the rapid override so you have more reaction time if something is configured incorrectly.

Lube system

If your system has an oiler, open Configure → Control → Settings and scroll to Lube System. Enable it, choose an action trigger, and set the output, run time, and time between cycles. Start conservative and increase.

Lube System settings example