Spindle Index Sensor

For
Seven Inch Mini-Lathes
 WARNING!
This document provides critical safety instructions regarding the installation of your Spindle Index Sensor.

Save this document for future reference. Failure to read, understand and follow these instructions may result
in fire or serious personal injury—including amputation, electrocution, or death.

There are serious hazards in the process and procedures necessary to convert a manual machine tool to a
computerized operation. Due to the overwhelming variety of circumstances under which these conversions
may be performed, no attempt has been made to identify all (or any number) of these hazards. The owner of
this Spindle Index Sensor is solely responsible for devising safe procedures for the installation of these
components. This responsibility includes but is not limited to proper installation in a safe environment,
personnel training and usage authorization, proper inspection and maintenance, comprehension of this
document, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal
protective equipment.

The installation of this Spindle Index Sensor may violate existing warranties associated with the manual
machine tool on which the Spindle Index Sensor is to be installed.

The Franco Kit, LLC will not accept liability for injury or property damage from negligence, improper training,
or misuse of the Spindle Index Sensor.

The Franco Kit, LLC will not accept liability for any injuries or damages that may result from installation and
operation of this Spindle Index Sensor and/or the equipment on which it is installed.

WARNING!
Dust created by power sanding, sawing, grinding, drilling, and other machining activities may contain
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Examples of these chemicals include but are not limited to:

• Arsenic and chromium from chemically-treated lumber.
• Lead found in lead-based paints.
• Crystalline silica from masonry products.

Your risk from these exposures may change depending on how often you do this type of work. Reduce
exposure to these chemicals by following these guidelines: Work in a well ventilated area, and work with
approved safety equipment such as dust masks that are specially designed to filter out microscopic particles.

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 WARNING!
Serious personal injury may result if the power is connected to the machine tool while installing this Spindle Index
Sensor. Always make sure the power is disconnected before performing any portion of the Spindle Index Sensor
installation. Do not connect power until the installation of the Spindle Index Sensor is complete. If it is necessary to
make adjustments to the Spindle Index Sensor after the initial installation is complete, disconnect machine from power
supply before making adjustments. This prevents an injury risk from unintended startup of the machine.

Do not attempt to install or operate the Spindle Index Sensor while under the influence of drugs or alcohol, when tired,
or when distracted.

ANSI-approved safety glasses or a face shield must be worn when installing and/or operating the Spindle Index Sensor.
Doing so will reduce the risk of eye injury or blindness from flying particles. Standard eyeglasses are NOT to be worn in
place of approved safety glasses.

Before installing and/or operating the Spindle Index Sensor make sure you are not wear clothing, apparel or jewelry that
can become entangled in moving parts. Long hair can become tangled up in moving parts resulting serious injury and
should be tied up or covered when near equipment.

Never operate the Spindle Index Sensor unattended. Reduce the risk of accidental injury by turning the machine OFF
and ensure all moving parts completely stopped before walking away.

Children should be kept away from the Spindle Index Sensor and any associated equipment during the installation
and/or operation of the equipment.

Be alert for malfunctioning equipment and perform regular inspections for damaged, loose or improperly adjusted
components – or any condition that may prevent the safe operation of the machinery. Immediately disconnect the
power if any unsafe conditions are detected. Make sure that all necessary repairs are completed before resuming the
use of the Spindle Index Sensor or any equipment on which it is installed.

Never leave wrenches or other tools in chucks or any type of rotating work-holding device as they may become
dangerous projectiles if the power is accidently turned on and the spindle begins to rotate.

Always be aware of the placement of your hands and fingers during the installation and/or operation of the Spindle
Index Sensor as they may be cut by sharp tools or pinched by moving machinery.

Electricity can be lethal. Never modify the electrical components of the manual machine on which the Spindle Index
Sensor is to be installed. Any electrical connections that must be made during the installation of the Spindle Index
Sensor (stepper motors, drivers, interface boards, etc.) should be performed by a licensed electromechanical technician.

All machine tools MUST have an Emergency Stop switch. Any additional electromechanical equipment attached to the
Spindle Index Sensor MUST be equipped with an Emergency Stop switch.

The information contained in this document is subject to change as improvements to the design are implemented.

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Installation
Description Qty Image
Spindle Index Sensor 1

Magnet 1
M5 Washer 1

The INDEX input is used to detect spindle RPM. It is required for threading and feed per revolution (G95
mode) feed rates. The spindle index sensor will mount to the mini lathe using existing threaded holes. It is a
PNP sensor and the connection between INPUT and GND is normally closed. When a magnet is placed in front
of the sensor, the connection will open and the input will be triggered.
WARNING! Disconnect the power from the lathe before installing the sensor. Remove the forward/reverse
gear assembly and mount the sensor as shown in Figure 2.
Make the electrical connections as shown in Figure 1. Many breakout boards will have a connector providing
+5V and as well as a ground (GND) connector. The input wire will connect to the input terminal of your
choice. Make sure that all wires are secured in such a way to prevent them from being caught by the rotating
spindle.
Mount the magnet to the spindle as shown in Figure 3 using an appropriate epoxy adhesive. The sensor is
polarized and will only be triggered by one side of the magnet – make sure you have the correct side of the
magnet facing the sensor before you permanently fasten it to the spindle. Carefully rotate the spindle making
sure the sensor is close to the magnet but not touching it. WARNING! Allow the epoxy to dry before
attempting to operate the lathe. Make sure the plastic cover is installed as this will protect you if the magnet
detaches from the spindle.
NOTE:
a. It is necessary to set the input to ACTIVE LOW as shown in Figure 4.
b. Relay Control must be enabled and outputs must be designated for M3 and M4 (even if you don’t
actually enable them). Mach3 will not display spindle RPM unless it thinks these outputs are being
used. See Figure 6.
c. INDEX DEBOUNCE must be adjusted to compensate for the duration of time the INDEX pulse is
triggered during each revolution. As RPM increases, the duration of the INDEX pulse will decrease. See
Figure 5.
d. In order to perform threading, Mach3 must see only 1 INDEX pulse per revolution and the PULLEY
RATIO must be set to 1. See Figure 7.
e. Mach3 will not display spindle RPM until you tell it the spindle is on by either commanding an M3 or
M4 or clicking the Spindle button.

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 +V GND INPUT
(5 to 24 volts)

Figure 1

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 Figure 2

Figure 3

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 Figure 4

Figure 5

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 Figure 6

Figure 7

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