Plug and Play CNC 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

Keyboard Jogging is not enabled in Mach4.

Turn the "Keyboard Jog" toggle to ON.

Avid CNC Mach4 Users Guide

Y Axis motor cable connections swapped at Plug and Play CNC Controller causing motors to rotate in opposite direction.

Swap Y1 and Y2 motor cables at Plug and Play Controller enclosure.

Motor & Sensor Connections

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

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 CNC Motor and Sensor Connections

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

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 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

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 Plug and Play CNC Controller.

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

Sensor Connection 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.

Sensor Connection Instructions

The CRP860-00E breakout board or ribbon cable is faulty.

Replace CRP860-00E breakout board and ribbon cable once the diagnosis is confirmed.

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.

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.

"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.