Mach4 CRP800 Controller¶

Mach4 has been designed to jog the machine using the arrow keys even while not selected as the primary window.

If this functionality is not desired, turn off keyboard jog prior to selecting another program.

Avid CNC Mach4 Users Guide

Mach4 is unlicensed.

Check license status.

Mach4 will only run for a limited time without a valid license. It may stop mid program with no warning or error message.

Mach4 Licensing

Soft limits or other limits may have been reached.

Check the message bar at bottom of Mach4 for error messages. If no message is present, check status history for past messages by clicking the History button in the bottom lefthand corner of the main Mach4 window.

The Auto-Z Touch Plate is not plugged into the AUX1 port on the Plug-and-Play Controller.

Ensure the Auto-Z Touch Plate cable is connected to the AUX1 port and fully seated and secured.

To test the Auto-Z Touchplate signal, place the magnet on the brass surface. If Mach4 is receiving the signal from the touch plate, the Probe Signal indicator below the Auto-Z Touch Plate button should change from Inactive to Active .

Mach4 installation may have been corrupted.

Restore backup profile from a date before potential corruption. A full reinstall may be required if a profile restore does not resolve the issue.

When reinstalling, it is recommended to upgrade to the latest version of Mach4.

Avid CNC Mach4 Download

Restore/Reset Instructions

Incorrect cutting tool option selected when configuring Mach4.

Select "Router" or "Spindle" from the dropdown in the Avid CNC Mach4 configuration window based on machine configuration.

Mach4 Configuration Instructions

The Avid CNC Mach4 Configuration window is overriding settings that differ from the predefined configurations when the Save button is clicked.

In instances where customization is desired, it is recommended that the machine be configured using the Avid CNC Mach4 Configuration utility. Once initial settings have been saved and functionally tested, reopen the configuration window. In the Custom tab, check the Disable Avid CNC Mach4 Configuration checkbox then click save.

That checkbox will ensure changes made to Mach4 settings will not be overwritten by the Avid CNC Configuration utility. It is strongly recommended that custom Mach4 profiles be backed up for easy recovery in the event of any future issues.

Custom Mach4 Configurations

Packaging a Mach4 Profile

Mach4 is in an "Enabled" state.

Disable Mach4.

Avid CNC Mach4 Users Guide

The configuration is locked by an operator lock.

Unlock Mach4 in Operator -> Unlock .

Keyboard Jogging is not enabled in Mach4.

Turn the "Keyboard Jog" toggle to ON.

Avid CNC Mach4 Users Guide

A proximity sensor is triggered when Mach4 is opened, preventing movement.

Option 1: Power down machine and manually move machine away from limit switch.

Option 2: In Mach4, navigate to the Jogging tab then click the Axes Limits Override button. Carefully jog the machine away from sensor.

With this override turned on, limit switches will not stop over travel toward switches. Jogging in the incorect direction may result in damge to sensors.

Mach4 Users Guide

Y Axis motor cable connections swapped at the Controller, causing motors to rotate in opposite direction.

Swap Y1 and Y2 motor cables at the Controller enclosure.

Section 9 of Assembly Instructions

CRP850-00E breakout board is not firmly seated into motor drivers, leading to motion in only one direction.

Reseat CRP850-00E breakout board into motor drivers to ensure all motors are receiving step and direction signals.

CRP850-00E breakout board is not firmly seated into motor drivers, leading to motion in only one direction.

Reseat CRP850-00E breakout board into motor drivers to ensure all motors are receiving step and direction signals

Motion may be briefly stalling due to the PC and Mach4 being overloaded by dense G-code.

To reduce the density of G-code without affecting real world results, increase the toolpath "tolerance" in the CAM software settings. Defaults are often 0.0004" - this should be increased to at least 0.001". In most cases the tolerance can be increased to 0.004" without visible effects.

The Mach4 motor or sensor mapping does not match the physical connections of motor or sensor wiring.

Ensure that all motor and sensor cable connections match the controller labeling and the chosen Mach4 configuration.

PRO 19.2 and later: Section 9 of Assembly Instructions

PRO 19.1 and earlier: Section 7 of Assembly Instructions PDF

Standard (All): Section 7 of Assembly Instructions

Benchtop PRO (All): Section 7 of Assembly Instructions

Benchtop Standard (All): Section 1.8 of Assembly Instructions PDF

Please do not hesitate to Contact Us for help resolving this issue.

Spindle Controller not connected to a power source or not turned on.

Check connection to the outlet, circuit breaker at the main panel, and power switch on Spindle Controller.

Motor enable/disable switch is in the 'Off' position.

Check switch position and set to the 'On' position.

Intermittent ethernet connection between Mach4 and the ESS due to a faulty ethernet cable, USB ethernet adapter, or USB port.

Perform the following tests to eliminate the ethernet cable/adapter as the cause of motion loss:

1. Test with known good cable, between computer and Plug & Play Controller.

2. Bypassing the panel mount connector on the Plug & Play Controller by plugging ethernet directly into the ESS board.

3. Test with a known good USB-to-Ethernet adapter or new adapter.

4. Test ethernet adapter plugged into an alternate USB port.

Replace cable or adapter if necessary.

Loose power supply wiring in the Plug and Play controller.

Turn off and unplug power from the controller.

Check the 5V and 12V power supply input and output wiring is secure. If necessary, reseat and firmly tighten connections.

Check the 5V power wiring on the ESS (12V on WarpRunner/TMC3in1 for Plasma controllers) and secure if necessary.

Loose breakout board connection in the Plug and Play controller.

Turn off and unplug power from the controller.

Check that the CRP850-00E breakout board is firmly seated in the motor drives.

For Plasma controllers, check that the WarpRunner or TMC3in1 breakout board is firmly seated in the ESS connection.

Loose motor control wiring in the Plug and Play controller.

Turn off and unplug power from the controller.

Check that all motor drive connections are secure.

Motor Drive Connections

The router model installed has soft-start functionality.

Routers with soft-start are not compatible with the solid-state relays used in the Plug and Play CNC Controller.

Refer to router manufacturer documentation to determine if router has soft start functionality.

Plug and Play CNC Controller Relay 1 In power cable not connected or not plugged into a wall outlet.

Double-check connection of power cable to Relay 1 In port on Plug and Play CNC Controller. Verify circuit breaker for the input power outlet has not been tripped at the main panel.

Relay 1 Setup

The input power fuse has blown.

Check fuse located in the black DIN rail mounted fuse block below the 48V power supplies.

Plug and Play CNC Controller Schematic

The soft limits are set too conservatively by default preventing the axis from reaching its true lower limit.

Note: This is most often seen on machines equipped with 12" Z Axis.

Option 1: Update Mach4 to latest version.

Option 2: Adjust the Z axis soft limit manually in Mach4 by navigating to: Configure -> Control -> Homing/Soft Limits.

Avid CNC Mach4 Download

There may be corruption of the network adapter settings that is causing connection interruptions.

Perform Windows Network Reset then rerun SCU application.

Network Reset Instructions

Proximity limit switches not connected to correct input ports.

Double-check the sensor cable connections at CNC Controller.

Note: A common mistake is swapping Y1 and Y2 sensor connections.

Section 9 of Assembly Instructions

The proximity sensor, sensor cable, or CRP860-00E breakout board is faulty.

Test sensor to ensure LED on sensor body illuminates when a metal object is placed in front of the sensor. If LED does not illuminate, test sensor attached to a different cable. If LED still does not illuminate, replace the sensor.

If known good sensor/cable combinations are unresponsive on a sensor input port, the CRP860-00E breakout board may be damaged. Contact Us for further troubleshooting and replacement parts.

Revision 19.2 and later: Section 9 of Assembly Instructions

Revision 19.1 and earlier: Section 7 of Assembly Instructions PDF

A proximity sensor may be triggered by debris.

Check the control PC for indications of triggered proximity sensors.

Clean any metal debris from around the proximity sensors.

Sensor flag or sensor not positioned correctly.

Ensure the sensor and/or sensor flag is positioned such that the sensor is triggered without contact between the moving assembly and rubber bumper.

Pro-Tip: CNC Proximity Sensors

Machine Assembly & Setup

Proximity limit switches not connected to correct input ports.

Double-check the sensor cable connections at Plug and Play CNC Controller.

Note: A common mistake is swapping Y1 and Y2 sensor connections.

For machine revision 19.2 and later: Section 9 of Assembly Instructions

For machine revision 19.1 and earlier: Section 7 of Assembly Instructions PDF

Proximity limit switch input pins improperly assigned.

To see what pins are receiving signals when a sensor is triggered, open Mach4 then select Diagnostics -> ESS -> Inputs

Ensure correct Avid Mach4 configuration is selected.

If not using Avid Mach4 configurations, ensure pins are mapped correctly in the ESS configuration

Axis homing order incorrectly assigned after Mach4 configuration.

Note: Assigning homing order is only necessary on multi-process and shared sensor port machine.

1. In the Avid CNC Mach4 Configuration menu, choose the "Use custom homing settings" option.

2. Set the axis homing order as needed so that axes sharing a sensor port do not home simultaneously.

Mach4 Custom Configuration Menu

Assigning Homing Order

Overly aggressive feed rate or depth of cut causing tool deflection.

Reduce feed rate and test again for accuracy. Speeds may also need to be adjusted to maintain the desired chip load.

This type of inaccuracy is most often seen with small diameter tooling or cutting tools with long cutting flutes.

Tool diameter was not set correctly in the touch plate dialog window.

Ensure the diameter entered matches the diameter of the tool being used and re-run the touch off routine.

Auto Z Touch Plate Tutorial

Toolpath was not regenerated after using the touch plate.

If G-code is loaded prior to setting X / Y zero, the toolpath will need to be regenerated to account for work offset prior to cutting.

Auto Z Touch Plate Tutorial

Incorrect motor selection made in Avid CNC Mach4 Configuration.

Our NEMA 23 and NEMA 34 R&P drives have different ratios of steps/inch. An incorrect selection will cause significant dimensional inaccuracy. Reconfigure Mach4 and select "NEMA 23" or "NEMA 34" motors based on machine configuration.

Mach4 Configuration Instructions

Unused height control setting in Mach4 can lead to incremental creep of Z Axis position.

Upgrading to the latest release of Mach4 will eliminate this issue. The latest version disables height control and includes bug fixes for improved reliability.

Avid CNC Mach4 Download

Overcurrent condition caused by the M23 spindle power cable between the Spindle Controller and Spindle not being plugged in correctly.

Unplug and reseat the spindle power cable on both ends. Make sure that the pins seat easily and are not bent out of place.

Spindle Connection Instructions

The 14-pin cable between the Plug and Play CNC Controller and Spindle Controller may not have continuity.

Check the VFD display to ensure no fault present (fxxx.x is the expected no-fault display). Reseat 14-pin cable at both the CNC Controller and Spindle Controller.

14-pin Cable Connection

Incorrect Mach4 configuration.

Ensure the correct version of Mach4 is being used (v2.0.9 or newer) and the “Spindle Type” is set to “8.7HP Avid spindle”.

If using Mach3, ensure the spindle pulley range is set to 0 - 24,000.

Loose connection of the 0-10V signal from the Plug and Play Controller and the VFD.

Check connection of the 0-10V signal wires at all connection points in the Plug and Play Controller and Spindle Controller. Check connection of the 14-conductor cable, reseating if necessary.

Plug and Play CNC Controller Schematic

Spindle Controller Schematic

The spoilboard program is too large or does not account for the portion of the work area extending past the front of the machine extrusion.

In Mach4 with work coordinates set and G-code loaded, click Regen Toolpath to the right of the toolpath preview window.

Inspect preview for cutting moves (green lines) or jog moves (white lines) that fall outside the machine work area (dashed yellow line).

Any lines outside the work area will trigger a soft limit error. If found, reprogram toolpaths to ensure the program stays within the set work area.

Mach4 has a "look ahead" feature which analyzes upcoming lines of G-code to ensure no command contains errors or exceeds the machine work area. The default setting is 20, meaning Mach4 is always reading 20 lines ahead. Because of this feature, a soft limit can be triggered well before the machine would have been commanded to move outside of the work area.

Program extents may be outside of the area defined by soft limits.

In Mach4 with work coordinates set and G-code loaded, click Regen Toolpath to the right of the toolpath preview window.

Inspect preview for cutting moves (green lines) or jog moves (white lines) that fall outside the machine work area (dashed yellow line).

Any lines outside the work area will trigger a soft limit error. If found, reprogram toolpaths to ensure the program stays within the set work area.

Mach4 has a "look ahead" feature which analyzes upcoming lines of G-code to ensure no command contains errors or exceeds the machine work area. The default setting is 20, meaning Mach4 is always reading 20 lines ahead. Because of this feature, a soft limit can be triggered well before the machine would have been commanded to move outside of the work area.

Generic Mach4 error, multiple VFD errors can cause this.

See Spindle and Spindle Controller troubleshooting section for specific fault codes and corrective actions

Check VFD screen for specific error code and refer to Spindle and Spindle Controller Troubleshooting Section .

A Windows permissions issue is preventing the installer from working as expected.

Right click on the Mach4 Installer (mach4-avidcnc-installer-2.x.x.exe) and select 'Run as administrator'

Avid CNC Mach4 Download

A limit switch was triggered when Mach4 started.

Use the "Axis Limits Override" button on the Jogging tab to move the triggered axis away from the limit.

Avid CNC Mach4 Users Guide

Mach4 profile or installation may have been corrupted.

Restore to a known good profile or reinstall Mach4.

Note: If using custom profiles or screen sets, save a copy of the Mach4 Hobby folder prior to reinstalling as some profiles may be usable after reinstall.

Restore Mach4 Profile

Reinstall Mach4

If the light on the sensor still works as expected when the sensor is manually triggered, there may be a short in a cable or circuit board.

Unplug the falsely triggered sensor at the controller and plug in another sensor/cable to that port.

If the error is cleared, there is likely a short in the cable.

If the error is not cleared, there may be a short inside the controller. Check the controller for metal shavings and Contact Us for support.

The dust collection hose may have triggered the proximity sensor. Dust hoses often contain metal coils.

Secure dust collection hose or shroud sensor such that a false limit cannot be triggered by moving hose.

Mach4 installation may have been corrupted.

Restore backup profile from a date before potential corruption. A full reinstall may be required if a profile restore does not resolve the issue.

When reinstalling, it is recommended to upgrade to the latest version of Mach4.

Avid CNC Mach4 Download

Restore/Reset Instructions

This behavior is inherent to the design of the ESS's integrated circuit and input pull-down resistors.

The message is expected, and no corrective action is needed.

This is normal behavior for Mach4.

The message is expected, and no corrective action is needed.

The Auto Z Touchplate is plugged into the controller A port instead of the correct AUX 1 port.

Plug the Auto Z Touchplate into the AUX 1 port on the Plug and Play controller.

The Mach4Core.dll file may have been falsely flagged by Windows Defender or other antivirus software.

It is recommended to disable the internet connection and all antivirus software on the control PC.

Otherwise, uninstall Mach4. Add an exception rule for the C:\Mach4Hobby folder in any active antivirus software. Reinstall Mach4.

Incorrect power up sequence. If Mach4 is started before the ESS is powered it will fail to connect.

Close Mach4 and power off the CNC Controller. In sequence:

1. Power on the CNC Controller

2. Start Mach4

If this occurs after a Windows update, the update may have caused issues with assigned addresses of ESS/adapters.

Perform Windows Network Reset then rerun SCU application.

Note: The SCU application can disable Windows updates. This is highly recommended for long term stability of control PC communication with ESS.

Network Reset Instructions

ESS may not be receiving appropriate power from power supply.

Check connection for loose connections from 5V power supply to ESS.

Check output voltage from 5V power supply using a multimeter. ESS will not function properly below recommended 5V input power.

Warp9 ESS Power Requirements

The ESS board is faulty.

Check signal LEDs on ESS. Please refer to the Warp9 page for LED documentation.

Warp9 ESS LED Documentation

Intermittent connection between control PC and ESS caused by a loose cable or ethernet adapter.

Double-check connection of ethernet cable and/or USB ethernet adapter.

If available, test with additional ethernet cable to ensure the cable is not faulty.

If using an adapter, test the adapter in an alternate USB port to ensure the port/adapter is functioning correctly.

ExpressVPN or another VPN client preinstalled by the PC manufacturer.

Check Network Adapter in SCU. If ExpressVPN or other VPN adapter is shown, uninstall VPN software, perform windows network reset, then re-run SCU application.

In the SCU there are multiple ESS networks and the 10.9.9.2 address network is "Down". Can be caused by running the SCU multiple times, or connecting ESS to a different network adapter.

Disable the unused network adapter in Windows "Network Connections".

Note: this is a good first step before doing a Network Reset.

"Already have standard network adaptor configured" error message.

Perform Windows Network Reset then rerun SCU application.

Network Reset Instructions

This issue is often caused by running the SCU multiple times.

Windows Network Reset can generally resolve this issue, the SCU will need to be re-run after the network reset is complete .

Network Reset Instructions

Ribbon cables between ESS and CRP850-00E breakout board swapped between Port 1 and Port 2 when reinstalled.

Double-check the connection of ribbon cables between ESS and CRP850-00E breakout board.

Port 1 -> Port 1

Port 2 -> Port 2

Power jumpers on Port 1 and Port 2 of ESS board are not installed onto both pins.

Note: In most cases, this is only relevant after the replacement of a faulty ESS board.

With the controller turned off, install Port 1 and Port 2 jumpers onto both pins.

ESS Port Jumper Information

Loose or inconsistent ethernet connection.

Check all connections in the ethernet chain from ESS to PC. Run the SCU application to ensure that the network is properly configured and communicating.

Chips from the metallic material are triggering the proximity sensors.

The limit switches can be disabled in Mach4 to resolve this issue.

NOTE: With the limit switches disabled, the machine will not stop if a sensor is triggered. This means that the machine can be physically crashed into the sensors and bumpers if commanded to do so. Disabling the limit switches will not impact homing, and soft limits will be enabled after homing to help avoid overtravel in any direction. Do not make this change until you are familiar with the machine and understand the risks associated with this change. Always home your machine prior to operation.

To disable the limit switches in Mach4, select Configure ➝ Avid CNC Mach4 Configuration ➝ Advanced Options , check the Disable all limits checkbox, then select Save .

If you have concerns or questions prior to making this change, please Contact Us

Material origin is defined at bottom of the material in CAM software.

Option 1: Reprogram with origin set at the top surface of the material.

Option 2: Set Z height with touch plate on spoilboard surface instead of the top surface of the material.

With a flat spoilboard, zeroing to the spoilboard surface will provide more accurate thickness in pocketed areas without accurately accounting for material thickness.

For example, shallower than expected dado depth can affect the overall outside dimensions of assembled cabinets. This can lead to an increase in the overall length of a run of cabinets.

Multiple causes

Use the Show Support Log and Copy to Clipboard buttons in the SCU to save the support log and email the results to support@avidcnc.com for more information.

The USB controller may need to be reset on the PC.

Power cycle the PC. Open the Device Manager and looks for USB devices to check that the computer has recognized the adapter.

Duplicate power options or firewall program is preventing the SCU application from saving settings.

Download and install the latest SCU.

Avid CNC SCU