PoLabs PoKeys57CNC User manual

PoKeys57CNC and Mach4
Step by step guide - a.k.a. beginners guide
Version: 13/12/2017

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SAFETY INFORMATION
This product is intended for integration by the user into a computer numerical control (CNC)
machine. It is the user's responsibility to assess the overall system design and address all safety
considerations that affect the users and equipment. 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.
This product is not guaranteed to be fail-safe. The system that this equipment is used with shall be
fitted with a separate means of fail-safe protection, emergency-stop capability and/or system power
removal. This equipment may be connected to dangerous power sources, including electrical power
sources. Dangerous voltage levels may be present at this equipment or at connected devices.
Measures must be taken to prevent persons from contacting voltage sources which may be present.
Equipment should be housed inside an enclosure suitable for the intended environment. Safety
interlocks should be provided to prevent any and all dangers to personnel.
CNC machine tools are inherently dangerous, and can cause injury to operators and maintenance
personnel. Operators and maintenance personnel shall be properly trained in the safe use, operation
and maintenance of such machines. Automated machines that this equipment may be used with can
move at any time. All persons exposed to such machines must understand the dangers that are
present.

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Table of contents
PoKeys57CNC and Mach4 –step by step guide ...................................................................................... 4
Getting familiar with electronic components ..................................................................................... 4
Stepper motors................................................................................................................................ 5
PoStep25-32 vs. PoStep60-256 ....................................................................................................... 6
PoPower24-100 or PoPower48-320? .............................................................................................. 8
PoKeys57CNC controller.................................................................................................................. 9
PoPower12-25 ................................................................................................................................. 9
Let’s start connecting ........................................................................................................................ 10
Power supply ................................................................................................................................. 10
Stepper motors.............................................................................................................................. 11
Make custom flat cables................................................................................................................ 12
Connect the stepper motor controllers and PoKeys57CNC controller ......................................... 12
Connect limit and home switches ................................................................................................. 14
Connect probe............................................................................................................................... 16
Connect E-stop switch................................................................................................................... 16
Connecting other signals with the PoKeys57CNC device.............................................................. 17
Connecting spindle controller ....................................................................................................... 19
Connecting spindle speed sensor.................................................................................................. 21
Connecting spindle encoder.......................................................................................................... 21
Enabling threading support........................................................................................................... 22
Connect other peripherals ............................................................................................................ 23
Final check and power up.............................................................................................................. 23
Mapping PoKeys digital IO signals to Mach4 IO............................................................................ 24
Basic configuration of the PoKeys57CNC device............................................................................... 25
Selecting PoKeys57CNC connection type...................................................................................... 25
Using USB connection ................................................................................................................... 26
Using Ethernet connection............................................................................................................ 27
Mach4 setup...................................................................................................................................... 30

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PoKeys57CNC 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.
This tutorial focuses on the electronic system of the CNC machine with software and leaves
out mechanical design. We will assume that the target CNC machine has 3 axes with one
motor per axis.
Getting familiar with electronic components
For a three-axis CNC machine you will need the following parts:
3x stepper motor (one per axis),
3x stepper motor driver (e.g. PoStep driver),
Stepper driver power supply (e.g. PoPower),
Controller power supply (e.g. PoPower12-25),
PoKeys57CNC controller,
Additionally (not necessary, but helpful):
PoPendant 1C with manual pulse generator,
PoNETkbd48CNC keyboard with 48 keys, designed for CNC operation,
CablePack PoKeys57CNC (connectors and flat cable set),
Limit switches and E-Stop button.

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Stepper motors
The motors vary in rated current and holding torque. As you can find out, not all stepper
motors have the same number of wires. The 4-wire stepper motor has 1 coil per phase and
8-wire has 2 coils per phase and can be run in parallel or serial mode. Parallel mode needs
higher current, has lower inductance and better torque. Serial mode needs lower current
and has lower torque. You can find a more detailed explanation about stepper motors here
(http://blog.poscope.com/stepper-motor-driver-user-manual-complete-edition/internet) or
on some other internet sites.
Nema 17 (SY42STH47-1684B Stepper Motor)
4-wire
Nema 23 (SY60STH86-3008 Stepper Motor)
8-wire

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PoStep25-32 vs. PoStep60-256
Stepper motors require voltages and/or currents that the controller simply can’t produce.
Therefore we need to use a stepper motor driver. This electronic device will transform your
movement instructions from a controller in to a sequence where the windings in stepper
motor will be turned on or off, resulting in motor motion. More on
http://blog.poscope.com/stepper-motor-driver/
PoStep25-32
PoStep60-256
● 0.5 to 2.5 A phase current
● up to 6.0 A phase current
● Simple current and microstepping setup with
jumper
● Simple setup of current, micro-step and other
settings with software via USB
● Compatible with 4, 6 and 8 wire stepper
motors of any voltage
● Compatible with 4, 6 and 8 wire stepper
motors of any voltage
●+10 VDC to +30 VDC power supply
●+10 VDC to +50 VDC power supply
● 1, 2, 4, 8, 16 and 32 micro-steps per step
● 1, 2, 4, 8, 16, 32, 64, 128 and 256 micro-steps
per step
● Mixed decay mode for smoother moving
of motors
● Mixed decay mode for smoother moving
of motors
● 3,3V and 5V logic compatible inputs
● 3,3V and 5V logic compatible isolated inputs
● 250 kHz maximum step rate
● 250 kHz maximum step rate
● 0 °C To 70 °C operating temperature
● 0 °C To 70 °C operating temperature
● LED Power, Error and Enable Indicator
● LED Power, VM, Status, Fault and Stal
indicator
● On board temperature sensor
● Improved thermal managing
● Improved thermal managing
● It can be driven from USB without controller
● Compact size: 50 mm X 52 mm
● Compact size: 54 mm X 75 mm
PoStep60 stepper motor drivers configuration
To configure the PoStep60 stepper motor drivers, download latest software pack PoStep60
(available on the PoLabs homepage under Downloads) and unpack it to your computer. The
application allows you to configure and control stepper driver’s parameters. You can also
test the operation of the driver without CNC controller.

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Connect PoStep60-256 with USB cable to your computer and run PoStep60v0.xx.exe. Use Driver
setup tab to configure driver. The selection boxes allow you to choose the microstepping
setting and motor currents setting. Once the values are entered, click on Write values to driver
to confirm changes. Do the same procedure for all drivers you will use.
You can check if the motor is wired correctly and if it works properly, in Step control tab. Set
the maximum speed with dial button. Click on Run button and move speed slider left or right
to command the motor rotation. More detailed describtion on
http://blog.poscope.com/stepper-motor-driver-user-manual-complete edition/

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PoPower24-100 or PoPower48-320?
Choose appropriate power supply, taking into account witch stepper motor and driver type
you are going to use.
Stepper motor type
SY42STH47-1684B
Nema 17
SY57STH56-4004A
Nema 23
SY60STH86-3008
Nema 23
Power Supply
PoPower24-100
PoPower24-100
or
PoPower48-320
PoPower48-320
Stepper driver
PoStep25-32
PoStep25-32
or
PoStep60-256
PoStep60-256

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PoKeys57CNC controller
PoKeys57CNC is a blend between general purpose PoKeys device and motor controller. The
device is targeted primarily for controlling up to 8 STEP/DIR signal driven motors (stepper
motors, servo drives, etc.) in various applications with the addition of powerful PoKeys
device features. Device contains dedicated connectors for connections with motor drivers,
pendants, (HD44780-compatible) LCD module etc. In addition, 5 analog inputs with 12-bit
resolution are available.
PoPower12-25
PoKeys57CNC requires external 6-26 V power supply to be connected to the board in order
for the device to operate correctly (device may not operate according to the specifications if
the external power supply is not present). For this purpose we can use PoPower12-25.

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Let’s start connecting
Power supply
Start connecting power supply part, but don’t plug it into the AC socket until all
connections are done.
You should consider some general rules. Use color coded cable to connect all
three AC plug wires (L, N and PE). L-brown, N-blue, PE- yellow/green. In some
countries colors can be different as described. Remember - the yellow/green wire
must be always and exclusively used for PE wire (Protective Earth)!
Hint. You can preserve one AC plug cable if you connect both PoPower AC inputs
in parallel.
Remove approx. 1 cm (1/3 inch) of insulation at wire end. Insert wire’s end into
power supply connector and use a screwdriver to attach.
Use red and black (blue) wires for DC voltage. Red for positive power supply lines
(+V) and black for negative power supply lines (-V, GND).
Connect DC outputs (+V, -V) from the PoPower24-100 or PoPower48-320 to
PoStep power supply connector. DC outputs from the PoPower12-25 connect to
PoKeys57CNC power supply connector. Use screwdriver to attach.
Power supply selection jumper on PoKeys57CNC board should be set on “EXT”