So I'm sure I'm not the first person in this position but here we go...

A few years back during COVID lockdowns I decided to take the plunge and order a CNC 6040 off eBay (from a place called chinacnczone-au). Originally the goal was to be able to mill/engrave prototype enclosures or mill a quick prototype PCB sometimes. I had no idea what I was doing so the packages I found on eBay looked like the easiest way to dive in. I quickly learned once it arrived though that USB was a mistake when trying to do levelling for PCB milling due to the lack of proper probing implementation and decided it wasn't worth the effort compared to just sending a file to JLCPCB or breaking out the ferric chloride. It's been OK for doing a bit of label engraving/milling cutouts on enclosures though.

When I first got it I was suspicious of the software license (and I've now seen the same name in the hall of shame here confirming it's not legit) but at the time wasn't sure if it was just a quirk of a reseller buying bulk licenses or something, plus I didn't want to change any of the software provided after jumping through so many hoops just to get it all working (it seems like they provided a lot of files that were required to make Mach 3 speak to their hardware). Now that I've got a better understanding of using it though (and have confirmed they're providing stolen software) I'd like to replace the controller with an ethernet based one and buy the software so I'm actually supporting the developer.

Currently I've got an XHC USB controller as well as their remote so I was tempted to buy the equivalent XHC ethernet controller hoping it might just drop in as a replacement with minimal changes to other hardware. Just wondering if anyone has done similar before? It doesn't need to be super amazing and expensive, I don't actually use the machine very often and it's just for rough prototype boxes, but if there's a strong reason not to buy one of these cheaper controllers it'd be good to know so I don't wind up with similar issues to having bought a USB controller.

And as far as ditching this version of Mach 3 for a proper version, is it generally pretty straightforward to get it talking to an ethernet controller? I guess what I mean is that even though there was a bit of back and forth with the seller it was essentially a plug and play system, whereas with the upgrade I'd be doing all the setup myself.

Thanks!

Hi David,

As you suspect you are indeed following the path many have taken before you and you are correct in assuming that Ethernet communication has certain advantages over USB. As for XHC, well, they do not provide customer support and their products although well made do have plugin / software issues which, to my knowledge, cannot be overcome.
My recommendation is that you seriously consider using the Warp9, ESS. Check out their website and you will find complete documentation on its installation and setup etc. Should you choose to purchase a genuine licence the ESS is also compatible with Mach4 which is perhaps the way to go.

https://www.warp9td.com/index.php

Tweakie.

Or you could stay with usb and get a UC100 from cncdrive.com. Make sure you get the genuine article not a clone. I use one on my mill and another on lathe. Probing works perfectly.

Good call on moving to Mach 4, I think I just had Mach 3 stuck in my head because that's what I've been using with what I have. I see the ESS has a software bundle available with Mach 4 as well, I'm assuming that's a legit license?

The UC100 does look interesting too but at first glance it looks like more stuffing around with separate breakout boards and whatnot whereas the ESS looks like it's basically ready to go out of the box

I guess the other option I've been wondering about is if my current setup could work better with a fresh setup on a proper version of Mach 3/Mach 4 given the only issue I have is the probing functionality. If I use a program called Autoleveller I can actually surface map just fine with what I have (it modifies the g code to add a probing script before the actual g code so Mach 3 then does a surface mapping pass and stores the height variables), I just can't seem to get Mach 3 to do it without this other program. Which makes me think there must be a way to do it, and if so I could keep my hardware as is and just sort out the software license.

I think from what I've read though the issue comes down to drivers for these controllers only supporting their hacked version of Mach 3?

The Warp9 ESS/Mach4 bundle does come with a legit license.

Both the ESS and UC100 recommend using a breakout board so it is pretty much even on that score but Ethernet does have advantages over USB.

Mach4 does have many advantages over Mach3 such as your requirement for Surface Mapping, etc. although many still prefer to use Autoleveler.

Its all decisions my friend 

Tweakie.