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General Mach Discussion / Re: Spindle won't start - pwm bumped to minimum setting - Advice please

« Last post by scottrich on April 21, 2026, 02:16:16 AM »

Since it works when you toggle “Step Low Active”, check:

Ports & Pins → Spindle Setup: make sure PWM is enabled and min PWM isn’t set too high
Try lowering Minimum PWM (e.g. 0 or very low)
Verify Output # for spindle is mapped correctly (Ports & Pins → Output Signals)
Check pulley settings (Config → Spindle Pulleys), max speed not set too low
Also confirm your S command in MDI (e.g. M3 S1000) actually outputs a valid speed

The “pwm bumped into minimum” error often happens when Mach3 can’t output a valid PWM within your defined limits.

Mach4 General Discussion / Mach 4 scale issues

« Last post by robertsears on April 20, 2026, 10:56:27 PM »

Hello,
I have a Harbor Freight mini mill that I converted into a 3-axis CNC machine using a Heavy Metal ball screw conversion kit and Automated Technologies electronics. For my workflow, I design parts in Fusion 360 and run them in Mach4. I also installed the Mach4 Mill post from Autodesk’s website into my local library.

To test the setup, I created a small bottle opener. However, every time I run the G-code, the finished part comes out at about half the intended size. The scaling is consistently off—the part is always noticeably smaller than the original design.

In my machine setup, the units are set to inches, while the unit mode is set to metric. I’m wondering if this mismatch could be the issue, or if my motor settings might be incorrect.

Motor settings:

Counts per unit: 40960.0
Velocity: 35 units/minute
Acceleration: 0.49 units/sec²

Motor specs:

200 steps per revolution (1.8° per step)
128 microsteps

My calculation:
(200 × 128) ÷ 0.625 = 40960 counts per unit

I’d appreciate any insight or suggestions on what might be causing this scaling issue.

Mach4 General Discussion / Re: page up, page down for z axis not working

« Last post by Tweakie.CNC on April 20, 2026, 10:47:24 AM »

Not sure this will help but…
In Diagnostic / Keyboard Inputs check that Page Up / Page Down illuminate when you press those keyboard keys. If not then change the key allocations (usually 33 / 34) to match your 540p keyboard.

Tweakie.

Mach4 General Discussion / Re: page up, page down for z axis not working

« Last post by jlroch on April 20, 2026, 08:59:21 AM »

is there no one that has any suggestions?

VIDEOS / Re: Greetings from Tokyo this spring.

« Last post by Tweakie.CNC on April 19, 2026, 01:16:28 AM »

Excellent work Yoshii - your builds just keep getting better

Spring is rapidly progressing here in the UK also, the daylight hours are getting longer, flowers are blooming, birds are singing and making their nests. It will soon be summer.

Tweakie.

VIDEOS / Greetings from Tokyo this spring.

« Last post by myoshii on April 18, 2026, 07:58:56 PM »

Spring is rapidly progressing in Tokyo, hinting at the intense heat of this summer. How is it in your country?

https://youtu.be/NTkY0HkL2p0

Mach4 General Discussion / Re: Tool height probing jitter

« Last post by FiveO on April 18, 2026, 12:20:40 PM »

if the upper link does not work for videos, use this: https://limewire.com/d/2c3Jx#pvVPYoUWnE

Mach4 General Discussion / Tool height probing jitter

« Last post by FiveO on April 18, 2026, 08:03:03 AM »

Hello!

Using Mach 4 4809 and ESS v285. Probing new tool with m200, also using same kind for m6 for tool change height. Problem is jerk/jitter after probing slow. Added two videos to bottom of this post that show the problem. What's the problem and how to get rid of it? Here is my m200 code:
function M200()

local inst = mc.mcGetInstance()

--------------------------------------------------------------------
-- CONFIG
--------------------------------------------------------------------
local ToolSetterHeight = -40.425 -- distance from toolsetter surface to real workpiece surface
local FastProbeFeed = 200
local SlowProbeFeed = 20
local BackoffDistance = 1 -- retract between probes
local ProbeClearance = 1 -- safety backoff after slow probe

mc.mcCntlSetLastError(inst, "M200: Tool zeroing start")

--------------------------------------------------------------------
-- REQUIRE ACTIVE TOOL (no offsets applied)
--------------------------------------------------------------------
local tool = mc.mcToolGetCurrent(inst)
if tool < 1 then
wx.wxMessageBox("No active tool selected. Set Tool DRO first.", "M200 ERROR")
return
end

--------------------------------------------------------------------
-- Ensure absolute distance & feed mode
--------------------------------------------------------------------
mc.mcCntlGcodeExecuteWait(inst, "G90")
mc.mcCntlGcodeExecuteWait(inst, "G94")

--------------------------------------------------------------------
-- Start probing DOWN from current Z (NO upward move!)
--------------------------------------------------------------------
mc.mcCntlSetLastError(inst, "M200: Fast probe")
mc.mcCntlGcodeExecuteWait(inst,
string.format("G31 Z-9999 F%d", FastProbeFeed))

--------------------------------------------------------------------
-- Backoff before slow probe
--------------------------------------------------------------------
mc.mcCntlGcodeExecuteWait(inst,
string.format("G91 G0 Z%.3f", BackoffDistance))
mc.mcCntlGcodeExecuteWait(inst, "G90")

--------------------------------------------------------------------
-- Slow probe
--------------------------------------------------------------------
mc.mcCntlSetLastError(inst, "M200: Slow probe")
mc.mcCntlGcodeExecuteWait(inst,
string.format("G31 Z-9999 F%d", SlowProbeFeed))

--------------------------------------------------------------------
-- Read probed position
--------------------------------------------------------------------
local probedZ = mc.mcCntlGetPoundVar(inst, mc.SV_PROBE_POS_Z)
if probedZ == nil then
wx.wxMessageBox("Probe never triggered. Check wiring and position.", "M200 ERROR")
return
end

--------------------------------------------------------------------
-- Final retract after probing
--------------------------------------------------------------------
mc.mcCntlGcodeExecuteWait(inst,
string.format("G91 G0 Z%.3f", ProbeClearance))
mc.mcCntlGcodeExecuteWait(inst, "G90")

--------------------------------------------------------------------
-- CALCULATE NEW WORK OFFSET ZERO
--------------------------------------------------------------------
local newWorkOffsetZ = probedZ + ToolSetterHeight

-- Set Z0 on currently active work offset
mc.mcCntlSetPoundVar(inst, 5223, newWorkOffsetZ) -- 5223 = G54 Z, 5243 = G55, etc., Mach4 handles active WCS

mc.mcCntlSetLastError(inst,
string.format("M200: New WCS Z0 set to %.4f", newWorkOffsetZ))

--------------------------------------------------------------------
-- MOVE UP TO MACHINE Z-HOME (YOUR REQUEST)
--------------------------------------------------------------------
mc.mcCntlGcodeExecuteWait(inst, "G53 G0 Z0")

--------------------------------------------------------------------
-- DONE
--------------------------------------------------------------------
wx.wxMessageBox(
string.format("M200 Complete:\n\nProbe Hit @ Z = %.4f\nNew WCS Z0 = %.4f",
probedZ, newWorkOffsetZ),
"M200 DONE")

end

if (mc.mcInEditor() == 1) then
M200()
end

Videos: https://limewire.com/?referrer=pq7i8xx7p2 , videos was to big to upload here.