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PoLabs PoKeys57CNCpro4x25 Step-By-Step Manual

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PoKeys57CNCpro4x25 and Mach4
Version: 1.00
Step by step guide - a.k.a. beginners guide

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Summary of Contents for PoLabs PoKeys57CNCpro4x25

  • Page 1 PoKeys57CNCpro4x25 and Mach4 Version: 1.00 Step by step guide - a.k.a. beginners guide...

  • Page 2: Safety Information

    The user assumes all responsibility for system design, including compliance with regulatory standards and codes issued by the applicable entities. PoLabs do not make any claims as to the suitability of this equipment for the user’s application. Serious personal injury or equipment damage can occur from the improper integration, installation or operation of this product.

  • Page 3: Table Of Contents

    PoKeys57CNCpro4x25 and Mach4 – step by step guide Table of contents PoKeys57CNCpro4x25 and Mach4 – step by step guide ................. 4 Getting familiar with electronic components ..................4 Stepper motors ..........................5 PoPower24-100 ..........................5 PoKeys57CNCpro4x25 controller ....................6 Let’s start connecting .......................... 7 Power supply ...........................

  • Page 4: Pokeys57Cncpro4X25 And Mach4 - Step By Step Guide

    PoKeys57CNCpro4x25 and Mach4 – step by step guide PoKeys57CNCpro4x25 and Mach4 – step by step guide In this tutorial we will describe a step by step procedure how to build your own electronic system for CNC Machine and use Mach4 software with PoKeys plugin to get your CNC up and running.

  • Page 5: Stepper Motors

    4-wire PoPower24-100 PoKeys57CNCpro4x25 requires external 22-26 V power supply to be connected to the board in order for the device to operate correctly. Choose appropriate power supply, taking into account witch stepper motor and which current setting you are going to use. It is recommended to use at least 100w power supply, so PoPower24-100 could be used.

  • Page 6: Pokeys57Cncpro4X25 Controller

    PoKeys57CNCpro4x25 and Mach4 – step by step guide PoKeys57CNCpro4x25 controller PoKeys57CNCpro4x25 is a blend between general purpose PoKeys device and motor controller as well as stepper motor driver. The device is targeted primarily for controlling up to 4 stepper motors in various applications with the addition of powerful PoKeys device features.

  • Page 7: Let's Start Connecting

    Use screwdriver to attach. Stepper motors Connect the stepper motor wires to the stepper motor driver outputs on PoKeys57CNCpro4x25; marked on the enclosure. Use a table below for 4 or 8-wire stepper motor. 4-wire stepper motor pin-out:...

  • Page 8: Connect Limit And Home Switches

    NPN (open-collector) type output. These can directly be connected to PoKeys57CNCpro4x25 inputs, as shown on the illustration below. Connect the GND of the sensor to GND of the PoKeys57CNCpro4x25 GND. Connect the sensor’s signal output to PoKeys57CNCpro4x25 input (IN) terminal. Connect sensor’s positive power supply to the 24 V positive terminal of the PoKeys57CNCpro4x25.

  • Page 9: Connect Probe

    Connect E-stop switch PoKeys57CNCpro4x25 is designed to include an emergency switch on the board – hence the dedicated connector for the emergency switch. The e-stop connector is wired in the same way as limit switches, without the 24V power supply.
  • Page 10 PoKeys57CNCpro4x25 and Mach4 – step by step guide External device optocoupler inputs - active low Compatible PoKeys signals: PoKeys pin marked as either of DO5, DO5_D, OCOC or REL type in PoKeys57CNC specifications - suggestion: use OCOC or REL Wiring for DO5, DO5_D: Connect PoKeys GND to common ground of the external device, connect PoKeys pin to external device input.

  • Page 11: Connecting Spindle Controller

    If your spindle controller only has an on/off control input and the spindle speed is either constant or manually adjusted, use the appropriate PoKeys pin to drive the spindle controller on/off control input (check chapter Connecting other signals with the PoKeys57CNCpro4x25 device on page 9 for more information).
  • Page 12 The 0-10V analog output signal of the PoKeys device is generated by low-pass filtering the PWM signal (on pin 17 in case of PoKeys57CNCpro4x25). Therefore, the signal is configured in PoKeys plugin for Mach4 under the ‘Miscellaneous’ tab. Set the PWM frequency to 20000 Hz, enable PWM on pin 17, select Pin 17 as the ‘Spindle output’...

  • Page 13: Connecting Spindle Speed Sensor

    PoKeys57CNCpro4x25 and Mach4 – step by step guide Connecting spindle speed sensor PoKeys57CNCpro4x25 expects that the spindle speed sensor outputs a digital signal with one (index) pulse per spindle rotation. Connect the spindle speed signal to PoKeys pin 13 (pin 5 of the Encoders connector –...

  • Page 14: Enabling Threading Support

    Enter the encoder resolution (in encoder ticks per revolution) in the field ‘Encoder’. Enabling threading support PoKeys57CNCpro4x25 supports threading operation with either index-only or encoder+index signals. Select ‘Enable threading support’ in the ‘Spindle’ tab of the PoKeys plugin configuration. Note that only lathe signal types for the spindle speed sensor can be selected.

  • Page 15: Connect Other Peripherals

    Connect other peripherals If you are going to use Pendant and/or Keyboard, connect it to CAN connector on PoKeys57CNCpro4x25 board. Make sure, that pendant has CAN enabled. Final check and power up After connecting all together, make some final check before plugging power supply cable into AC socket.

  • Page 16: Mapping Pokeys Digital Io Signals To Mach4 Io

    PoKeys57CNCpro4x25 and Mach4 – step by step guide Mapping PoKeys digital IO signals to Mach4 IO PoKeys pins can be mapped to Mach4 digital input and output signals via the Config > Mach4 > Input signals or Outputs signals menu/configuration dialog.

  • Page 17: Basic Configuration Of The Pokeys57Cncpro4X25 Device

    • Convenience: since most of computers have built-in USB ports, connecting the PoKeys57CNCpro4x25 to a PC via a USB cable is the most convenient solution. However, this requires that the computer is in close proximity to the machine. On the...

  • Page 18: Using Usb Connection

    PoKeys57CNCpro4x25 and Mach4 – step by step guide Using USB connection Step 1: Locate a free USB 2.0 port on your computer (1) and PoKeys57CNCpro4x25 board (2) and connect them with a standard USB cable. Step 2: Connect the PoKeys57CNCpro4x25 board to an appropriate power supply (3).

  • Page 19: Using Ethernet Connection

    Direct ethernet connection PoKeys57CNCpro4x25 – PC Make sure that an appropriate IP address is assigned to a network card of your PC, that the PoKeys57CNCpro4x25 device is connected to. Follow the steps, described in the following guide: Change TCP/IP settings in Windows 7.
  • Page 20 4 devices that have been detected – one PoKeys57U device, one PoKeys57E device and two PoKeys57CNCpro4x25 devices. By clicking on the PoKeys57CNCpro4x25 device entry, the device data section on the right of the dialog will show device details, including currently assigned IP address.
  • Page 21 PoKeys57CNCpro4x25 and Mach4 – step by step guide The autoconfiguration can be disabled in network device settings dialog under ‘Advanced’ options (by checking the ‘Disable automatic cross-subnet detection’ option). If automatic device discovery option is disabled, the software will not be able to automatically detect PoKeys devices in the network and a correct IP address of the device will be needed to connect to it.

  • Page 22: Mach4 Setup

    We will use Mach4 for this demonstration. 1. Download Mach4 and install it on your computer. 2. Download Mach4 PoKeys plugin (the latest version is available on PoLabs homepage under Downloads). Copy both plugin files and place them inside “Plugins” folder which is found inside Mach4 installation folder.
  • Page 23 PoKeys57CNCpro4x25 and Mach4 – step by step guide 4. Select your Pokeys device and click Next 5. In Motor drivers are already selected, under Pulse engine options Peripheral options PoPendant and/or PlasmaSensDiv can be selected, if you are using one. You can also rename your device if you want.
  • Page 24 PoKeys57CNCpro4x25 and Mach4 – step by step guide 7. Please restart Mach4 software. When Mach4 starts, ‘E-Stop condition!’ or ‘E-stop due to limit switch!’ text may appear in status list in the lower left corner of Mach4 window. This can happen due to the following causes: o E-Stop switch is pressed: to enable Mach4, release the E-stop switch o Polarity of E-stop switch is not configured correctly –...
  • Page 25 PoKeys57CNCpro4x25 and Mach4 – step by step guide 8. It is recommended to restart Mach4 after making major changes in plugin (changing device, adding new device, changing Pulse engine type etc). 9. Configure the Mach4 with the correct settings for your machine and motors – open Configure >...
  • Page 26 PoKeys57CNCpro4x25 and Mach4 – step by step guide • Option 2: select tab, click on Load G Code button and select FileOps roadrunner.tap from folder and then press button. Mach4Hobby\GcodeFiles Cycle Start Open user manual “PoKeys plugin for Mach4” that is provided with the Mach4 plugin for description of other available settings for the PoKeys device in Mach4.
  • Page 27 5. PoLabs devices may be used in equipment that does not impose a threat to human life in case of the malfunctioning, such as: computer interfaces, office equipment, communications equipment, test and measurement equipment, audio and visual equipment, home electronic appliances, machine tools, personal electronic equipment, and industrial robots.

This manual is also suitable for:

Mach4