CSMIO/IP-S

6-axis CNC controller

(step/dir)

HARDWARE VERSION (software supported): FIRMWARE VERSION (software supported):

v2 (Mach3) v2.020 - v2.910 (Mach3)
v2 FP4 (simCNC, Mach3, Mach4) v3 (simCNC, Mach4)

© copyright CS-Lab s.c. 2018: Rev 3.0

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CONTENT
1. General ............................................................................................................................................... 5
1.1 Signs used in this guide ............................................................................................................... 6
1.2 Content ....................................................................................................................................... 6
1.3 Standards compliance ................................................................................................................. 7
1.4 Specification................................................................................................................................ 7
2. Safety .................................................................................................................................................. 8
2.1 Example of direct E-Stop Signal connection................................................................................ 9
2.2 Example of E-Stop Signal connection using PILZ module .......................................................... 10
3. Recommendations for mechanical installation................................................................................. 11
3.1 Examples of components arrangement in a control cabinet. ................................................... 11
3.1.1 Block scheme pictorial view ............................................................................................... 11
3.1.2 Control cabinet made by CS-Lab Company ........................................................................ 12
4. Connectors, controls and electrical installation of the device .......................................................... 13
4.1 Connectors arrangement on the device ................................................................................... 13
4.2 STEP/DIR controlling signals connector (CSMIO/IP-S v2) .......................................................... 14
4.2.1 Signals on a Terminal Block connector .............................................................................. 15
4.2.2 Example – M542 drive connection .................................................................................... 15
4.3 Digital outputs connector (0-15) (CSMIO/IP-S v2) .................................................................... 16
4.3.1 Output circuits construction .............................................................................................. 17
4.3.2 Signals on a Terminal Block connector .............................................................................. 17
4.3.3 Examples – spindle switching signal .................................................................................. 18
4.4 Digital inputs connector (0-15) (CSMIO/IP-S v2) ....................................................................... 19
4.4.1 Input circuits construction. ................................................................................................ 20
4.4.2 Signals on a Terminal Block connector .............................................................................. 20
4.4.3 Examples of input signals connection ................................................................................ 21
4.5 Digital inputs connector (16-31) (CSMIO/IP-S v2) ..................................................................... 23
4.6 Analog inputs/outputs connector ............................................................................................. 24
4.6.1 Signals on a Terminal Block connector .............................................................................. 24
4.6.2 Example – connection and configuration of potentiometers ............................................. 25
4.7 Expansion modules connector .................................................................................................. 26
4.8 Power connector....................................................................................................................... 26
4.9 Communication connector – Ethernet...................................................................................... 27
4.10 Recommended cables ............................................................................................................... 28
4.11 Installation examples ................................................................................................................ 29
4.11.1 Inverter connection using analog output........................................................................... 29
4.11.2 Illustrative diagram of XYZ plotter (CSMIO/IP-S v2) ........................................................... 30

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4.11.3 Automatic control of drives power supply (HV) ................................................................. 32

4.12 LED lights meaning .................................................................................................................... 33
4.12.1 Types and location of the LEDs .......................................................................................... 33
4.12.2 State diodes description - STATx ........................................................................................ 34
5. Recommendations and drives selection (motors drives).................................................................. 35
6. Precise homing with encoder INDEX signal ...................................................................................... 37
6.1 Solution no. 1 – Homing on “index” function ........................................................................... 37
6.2 Solution no. 2 – Synchronization of HOME signal in servo drives. ............................................ 38
7. LAN connection and configuration ................................................................................................... 40
7.1 Direct connection to PC ............................................................................................................ 40
7.1.1 Windows®XP configuration. .............................................................................................. 40
7.1.2 Windows® 7 configuration. ............................................................................................... 41
7.2 Local network with router and DHCP. ....................................................................................... 44
8. Mach3 software – general information ............................................................................................ 45
8.1 Recommended PC configuration .............................................................................................. 47
9. Software installation ......................................................................................................................... 48
9.1 Mach3 installation .................................................................................................................... 48
9.2 Microsoft® .Net installation (older operating systems) ............................................................ 49
9.3 Installation of CSMIO/IP software ............................................................................................. 49
9.4 Administrator rights in Windows® Vista and Windows® 7 ........................................................ 51
10. Mach3 software configuration ....................................................................................................... 52
10.1 Configuration profile creation ................................................................................................... 52
10.2 The first run .............................................................................................................................. 53
10.3 Configuration of axes used in a machine .................................................................................. 55
10.4 Configuration of digital input signals ........................................................................................ 56
10.5 Configuration of digital output signals ...................................................................................... 58
10.6 Configuration of spindle and cooling ........................................................................................ 60
10.6.1 Analog output configuration ............................................................................................. 60
10.6.2 Problematic PWM Control function ................................................................................... 61
10.7 Configuration of resolution, speed and acceleration ................................................................ 62
10.8 Configuration of directions, homing and software limits. ......................................................... 64
10.9 Configuration functions in a plug-in window ............................................................................ 65
10.9.1 Axes special functions........................................................................................................ 65
10.9.2 Spindle configuration......................................................................................................... 68
10.9.3 Override sources – feed speed and spindle revs corrections source selection ................... 69
10.9.4 Plasma – additional functions for plasma cutters ............................................................. 70
10.9.5 Misc IO – Special functions related to I/O.......................................................................... 70
10.9.6 Other plugin functions ....................................................................................................... 71

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10.10 Selection of inch/mm units ....................................................................................................... 73

10.11 Some parameters in the General Config window. .................................................................... 73
11. First tests........................................................................................................................................ 75
11.1 Checking the input signals ........................................................................................................ 75
11.2 Verification of axes scaling and motion directions.................................................................... 76
11.3 HOMING and software limit switches test ................................................................................ 77
11.3.1 First homing ...................................................................................................................... 77
11.3.2 SoftLimit switches.............................................................................................................. 77
11.4 Test of spindle and cooling. ...................................................................................................... 78
12. Sample treatment step by step ...................................................................................................... 79
12.1 Project and G-Code files preparing ........................................................................................... 79
12.2 Preparing machine and Mach3 software .................................................................................. 83
12.3 We begin the treatment ........................................................................................................... 85
13. A few practical notes about Mach3 software and CSMIO/IP-S ...................................................... 87
14. VisualBasic® macros ........................................................................................................................ 89
14.1 Automatic tool-length measurement ....................................................................................... 89
14.1.1 Configuration..................................................................................................................... 90
14.2 Automatic tool change macro................................................................................................... 91
Addition A – Slave axis configuration example ..................................................................................... 92
Defining axes used in Mach3 software ............................................................................................... 92
Axis scaling and configuration ............................................................................................................. 92
Activation and choice of slave axis ...................................................................................................... 92
LIMIT and HOMING switches .............................................................................................................. 93
Axis direction settings ......................................................................................................................... 93
Manual feed test ................................................................................................................................. 93
Automatic reading of HOME switches position difference ................................................................. 93
Geometry correction mode activation ................................................................................................ 93
Addition B – CSMIO/IP-S firmware update ........................................................................................... 94
How to check current firmware version .............................................................................................. 94
Update application (uploader) ............................................................................................................ 94
Plugin file update ................................................................................................................................ 95
Update verification.............................................................................................................................. 95

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1. General

CSMIO/IP-S motion controller was designed for professional customers, who want to equip their
machine tool with an efficient, stable and flexible CNC control system for a reasonable price.
Our main goal is to achieve operation stability – hence the PC connection via Ethernet (its physical
layer is galvanically isolated and protocols we use ensure reliable and fast transmission even in tough
industrial environment). Practically any other interfaces do not provide the continuity and reliability of
transmission on such a high level as the ETHERNET. That is why it is currently the worldwide standard
for high-speed digital communication.
Another important goal was simplicity of installation. CSMIO/IP-S does not require any external elec-
tronics for proper operation. Inputs/outputs signals are inside optically isolated, filtered, protected
against short circuit, overheating etc. All signals are adjusted to industry standard 24V. The device is
enclosed in a compact cover, mounted on a DIN-rail, what makes that mechanical and electronic in-
stallation in a control cabinet takes less time and is even simpler.
CSMIO/IP-S product can work with three different control software: simCNC (by CS-Lab), Mach3 and
Mach4 (by ArtSoft Newfangled Solutions). The oldest and the best known is Mach3 software. As it
showed up it provided great ability to adapt to specific requirements at low price. This way it became
very popular. Mach4 software provides even better flexibility, better stability of work and more fea-
tures.
Basing on many years of experience with many different types of CNC machines CS-Lab created the
simCNC software as an alternative to Mach3 and Mach4. It provides features that many users could
not get using other CNC control software. In between the S-curve profile which allows to keep very
high axis accelerations without any noticeable knocking in a drive train system. Advanced optimization
and precision algorithms help you to achieve unusual dynamics and accuracy of machining. simCNC is
professional and on the other hand, simple to use. It provides reliability and maximum efficiency
(treatment is fast, dynamic and precise). SimCNC software is still actively developed to be the best
solution to replace the very expensive top control systems for CNC machines.
CSMIO/IP-S supports the popular step/direction standard (step/dir) as the drivers control interface. It
can control both the stepper motor drives and the most modern servo drives. Frequency of stop signal
that reaches to 4MHz (Mach3) or up to 8MHz (simCNC, Mach4) provides maximum advantage of
stepper division in stepper motors still reducing resonance and significantly improving performance of
propulsion system. It also allows for taking full advantage of encoders with large number of pulses per
rotation in servo drives, and the same lets you to achieve such precision and speed, which previously
were unavailable in this price sector.

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1.1 Signs used in this guide

Potential danger, possible injury risk

Useful information, tips

Warning, failure to comply with these warnings may lead to inappropriate functioning or dam-
age of the device

1.2 Content

The CSMIO/IP-S set includes terminal block adapters for easier wires connection in a control cabinet.
More content details below:

1. CNC CSMIO/IP-S Controller 6. DB9 connection tape (1 pc.)

2. 2xDB25 Terminal Block adapter 7. „Phoenix” 3 pin power plug (1 pc.)
3. 2xDB25 + 1xDB9 Terminal Block adapter 8. CD with electronic version of user guides
4. Ethernet connection wire and firmware (always check if there is a
5. DB25 connection tape (4 pcs.) newer version on www.cs-lab.eu )

If you can't find any of these parts in your package please contact your supplier.

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1.3 Standards compliance

CSMIO/IP-S controllers were designed and made in accordance with national and international stand-
ards for industrial control systems based on electronic components:
• Detailed requirements for programmable controllers: working characteristics, shock re-
sistance, safety etc. EN61131-2 (IEC1131-2), CSA 22.2, UL508
• Compliance with European Guidelines (low voltage, level of electromagnetic interference
Electromagnetic Compatibility), the CE marking.
• Electrical and non-combustible properties of insulation materials: UL 746C, UL 94, etc.
• The Product made in lead-free technology, RoHS compliant.

1.4 Specification

PARAMETER VALUE
Number of digital inputs 32
Number of digital outputs 16
Number of analog inputs 4
Number of analog outputs 2
Supply voltage 24VDC +/-10%
Power consumption 5W
Maximum voltage on in/out lines 30VDC
Maximum load of an output line 250mA
A voltage range of analog inputs 0-10VDC
Maximal load of analog output 5mA
Axis drives control type STEP/DIR [RS422]
Maximum frequency of a STEP signal 4MHz
STEP signal duty cycle 50%
PC connection Ethernet 10/100Mb
Ambient temperature range 0oC to +60oC
Relative humidity 10% do 95% (without condensation)

The STEP outputs signals frequency are in no way limited by the „Kernel speed” settings in Mach3
software. While using the CSMIO/IP-S controller this Mach3 configuration parameter is unused and
can be set on any value.

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2. Safety

CSMIO/IP-S device is powered by 24V safe voltage. I/O control lines are optically isolated, also PC con-
nection is galvanically isolated. The device does not constitute direct threat to health and life of a user.
Designing a complete control system (control cabinet), you should draw attention to several issues, so
that the entire system does not pose any hazard during use.

Always use NC contacts (Normal Closed) for limit switches and safety switch. Thanks to it - a wiring
mistake or i.e. plug-ins disconnection will stop the machine.

Pay special attention to an emergency stop circuit. Control system must be designed in such a way
that when you press an emergency stop mushroom, controlled machine stops immediately in all axes.
You should also take into account the possibility of failure of particular system components such as
main controller, or axis drives.
For that you can use a standard safety relay (it's not required, it's an option). The safety switch mush-
room, FAULT signals of drives and inverter and eventually other alarm signals – you should connect to
input circuits. Output or outputs should be connected to CSMIO/IP-S controller, and defined as emer-
gency stop. Outputs of security module should be also connected to axis drives, inverters, etc. This
way we get double protection – if, by inappropriate configuration or CSMIO/IP-S controller failure - the
emergency would not work, then information goes to axis drives, which can properly respond to it. It
works both sides: if drives would not react, you always have the controller.

The CSMIO-IP/S Controller in active state on the input line - defined as E-Stop, blocks the STEP signals
within 0.0005 s. It happens autonomously, without Mach3 software and thus the machine stops very
fast. The same happens with reaction to signals from limit switches.

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2.1 Example of direct E-Stop Signal connection

In the example above we used direct emergency signals connection. Such a connection is very easy
and at the same time, it ensures satisfying safety level. Of course, the easiest way is to connect the E-
Stop only to CSMIO/IP-S but then we lose double protection and it is no longer so safe solution.

As a switch (mushroom) of emergency stop always use special switchers, specially designed for that.
They have different construction and you can be actually 100% sure that the circuit will be discon-
nected after pressing the mushroom. Using common NC contacts is dangerous. It is worth to use con-
tacts from reputable companies. They are a little bit more expensive but their quality is much, better.

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2.2 Example of E-Stop Signal connection using PILZ module

PILZ
PNOZ X7 24 V

Above you can see an example of E-Stop signal connection to the CSMIO/IP-S controller and to the axis
drives, using Pilz company safety relay (PNOZ X7 24V symbol). S1 is a reset button (switching on the
safety relay), S2 is the emergency stop. The safety relay is an option, it's not required.
This module has one input, and due to it, all the alarm sources are connected to this input (A1). In
addition to the mentioned emergency stop (S2) there are NC contacts - NC1 and NC2, which may be,
e.g. opening sensors for a cover and a control cabinet. Moreover, there are drives FAULT signals con-
nected in series. Two outputs of the safety relay were used as the E-Stop signal for the CSMIO/IP-S
controller and axis drives.
This combination assures that machine stops in case of failure on any axis (FAULT signals of the
drives), by pressing the emergency stop mushroom and opening the cabinet or the cover. Separation
of output channels of the safety relay gives double protection to a system and significantly increases
reliability of the entire system.

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3. Recommendations for mechanical installation

CSMIO/IP-S controller and DB->Terminal block connectors were designed to be installed on a standard
DIN-rail. It is the quickest and the best way of installation.
The Controller uses a small amount of electricity and creates a negligible amount of heat. Aluminum
housing provides adequate cooling for electronics inside, even if an ambient temperature reaches
40OC.
As for the controller, there are no special precautions for ventilation and minimum distances. Howev-
er, usually, next to the controller in a control cabinet, there are also inverters, power supplies, motor
drives - these components emit a lot of heat, so you should always remember about their proper
location and proper ventilation of the cabinet.

3.1 Examples of components arrangement in a control cabinet.

3.1.1 Block scheme pictorial view

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3.1.2 Control cabinet made by CS-Lab Company

Caution is advised during mechanical and electrical installation. Poorly tightened cable may cause
many problems, it is also very difficult to find such a defect while launching/using the system.

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4. Connectors, controls and electrical installation of the device

4.1 Connectors arrangement on the device

Signals that control the Analog inputs and

Digital inputs 16-31
drives (STEP/DIR) outputs (0-10V)

Expansion modules
connector

Power connector

Digital inputs 0-15 Digital outputs 0-15 Communication con-

nector (ETHERNET)

Detail description of signals on each connector is placed in the next sections.

DB Terminal block connectors have the same pin numbers as DB connectors in CSMIO/IP-S device.
In example: 15 pin of DB25 connector match with the 15 pin on the terminal block.

If your CSMIO/IP controller is older than 2012: There were some hardware improvements made in the
CSMIO/IP-S v2 controllers therefore the pin topology on STEP/DIR, DIGITAL OUTPUTS and DIGITAL
INPUTS connectors is different for version v1 and v2. To define your version of the controller read the
first 4 figures of a serial number.
• Numbers starting with 1119… and below means version v1
• Numbers starting with 1120… and above means version v2
• Since 2015 there has been the FP4 version for Mach4 and simCNC software support (FP4
sign placed on CSMIO/IP front panel)

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4.2 STEP/DIR controlling signals connector (CSMIO/IP-S v2)

CSMIO/IP-S controllers v2 have serial number starting with 1120… and above.

PIN number Details

1 DIR[0]+
2 STEP[0]+
3 DIR[1]+
4 STEP[1]+
5 DIR[2]+ Do not ever connect differential out-
6 STEP[2]+ puts together!
7 DIR[3]+ Signals signed as „-„ cannot be con-
8 nected to GND as it will cause device
STEP[3]+
damage.
9 DIR[4]+ If you have never connected differen-
10 STEP[4]+ tial outputs you must read our addi-
11 DIR[5]+ tional documentation necessarily:
12 STEP[5]+ „CSMIO/IP differential outputs”
where are shown possible kinds of
13 GND
connection to different type drives. .
14 DIR[0]-
15 STEP[0]-
16 DIR[1]-
17 STEP[1]- The 5V power that is available on this
18 DIR[2]- connector has low permissible load
19 STEP[2]- (50mA / pin) and serves only to con-
20 trol the LEDs in the optically isolated
DIR[3]-
inputs of motor drivers.
21 STEP[3]-
22 DIR[4]-
23 STEP[4]-
24 DIR[5]- Pay attention to version of the con-
25 STEP[5]- troller

During STEP/DIR signals connection to a drive (both servo and stepper) you should pay attention to
which STEP edge is active. In the controller, a rising edge is the active edge so it is STEP+ signal change
from "0" to "1". Connecting the controller e.g. of M542 stepper motor you should connect the PUL+
signal to STEP+, and STEP- output with CSMIO/IP-S to the PUL- of the controller. This way switching on
the optocoupler in M542 will follow at rising edge of CSMIO/IP-S STEP signal. Improper connection
may cause position errors.

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4.2.1 Signals on a Terminal Block connector

By default, axes are assigned to following chan-

nels STEP/DIR: X[0] / Y[1] / etc.
Pin numbers Entered in Mach3 software in
Port&Pins” on „Motor Outputs” tab do not mat-
ter. If you want to assign other STEP/DIR channels
numbers to an axis, you should do it in the
plugin's configuration: menu „ConfigConfig
PlugInsCONFIG”.

4.2.2 Example – M542 drive connection

In the example below there was shown connection of M542 drives as X drives.

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4.3 Digital outputs connector (0-15) (CSMIO/IP-S v2)

CSMIO/IP-S controllers v2 have serial number starting with 1120… and above.

PIN number Details

1 24V power supply for 0-3 outputs
2 Output 0
3 Output 2
4 24V power supply for 4-7 outputs
5 Output 4
6 Output 6
7 24V power supply for 8-11 outputs The outputs have 250mA permissible
8 Output 8 load. Pay attention if you are con-
nected to a large inductance you may
9 Output 10
need to use an additional surge led,
10 24V power supply for 12-15 outputs preferably as close to the coil as pos-
11 Output 12 sible.
12 Output 14
13 GND (not in use)
14 Power supply 0V for 0-3 outputs
15 Output 1
16 Output 3 In Mach3 „Port&Pins” configuration,
17 Power supply 0V for 4-7 outputs the value in „Pin” column does not
mean a pin number in CSMIO/IP
18 Output 5
connector but it means output num-
19 Output 7 ber.
20 Power supply 0V for 8-11 outputs It means that entering „9” refers to
21 Output 9 output 9, and so Pin 21 in CSMIO/IP
connector.
22 Output 11
23 Power supply 0V for 12-15 outputs
24 Output 13
25 Output 15

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4.3.1 Output circuits construction

As you can see on the scheme, each input
is optically isolated. Outputs are divided
into groups, four in each group.
Each group is controlled by specialized
chip VNQ860. These chips work in PNP
logic, thus the active state is a high state
(+24V).
VNQ860 circuits are not powered from the
same source CSMIO/IP is. If they were, the
opto-isolation would have no sense.
Therefore, we must remember to supply
power to each group of outputs we use.

If we do not care about CSMIO/IP controller and digital outputs supply potentials separation and we
want to use one supply source then we can link power supply of all the groups (pins 1, 4, 7, 10) and
connect to controllers +24V supply. Of course you must also connect supply primary lines, 0V (pin 14,
17, 20, 23) to GND of CSMIO/IP controller power supply.

4.3.2 Signals on a Terminal Block connector

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4.3.3 Examples – spindle switching signal

In the example below, basing on spindle switching output configuration (M3) we can see exactly fol-
lowing dependency: [Mach3 software signal]  [CSMIO/IP signal]  [Pin in CSMIO/IP connector]

PIN number Description

1 24V power for outputs 0-3
2 Output 0
3 Output 2
4 Power 24V for outputs 4-7
5 Output 4
6 Output 6
7 Power 24V for outputs 8-11
8 Output 8
9 Output 10
10 Power 24V for outputs 12-15
11 Output 12
12 Output 14
13 GND (not used)
14 GND 0V for outputs 0-3
15 Output 1
16 Output 3
17 GND 0V for outputs 4-7
18 Output 5
19 Output 7
20 GND 0V for outputs 8-11
21 Output 9
22 Output 11
23 GND 0V for outputs 12-15
24 Output 13
25 Output 15

Outputs group power Output no. 5 of CSMIO/IP

(4 – 7) Controlling Signal (e.g. for inverter)

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4.4 Digital inputs connector (0-15) (CSMIO/IP-S v2)

CSMIO/IP-S controllers v2 have serial number starting with 1120… and above.

PIN number Details

1 Input 0 (+)
2 Input 2 (+)
3 Input 4 (+)
4 Input 6 (+)
5 Inputs 0-7 (-)
6 Input 8 (-)
7 Input 9 (-)
Pay special attention to not exceed
8 Input 10 (-)
the permissible voltage (30VDC) on
9 Input 11 (-) the inputs lines. It may cause the
10 Input 12 (-) device damage.
11 Input 13 (-)
12 Input 14 (-)
13 Input 15 (-)
14 Input 1 (+)
15 Input 3 (+)
16 Input 5 (+) In Mach3 „Port&Pins” configuration,
17 Input 7 (+) the value in „Pin” column does not
18 Input 8 (+) mean a pin number in CSMIO/IP con-
nector but it means output number.
19 Input 9 (+)
It means that entering „10” refers to
20 Input 10 (+)
input 10, and so Pin 20(+) and 8 (-) in
21 Input 11 (+) CSMIO/IP connector
22 Input 12 (+)
23 Input 13 (+)
24 Input 14 (+)
25 Input 15 (+)

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4.4.1 Input circuits construction.

You can see below simplified scheme of CSMIO/IP-S input circuits. On the scheme outputs: 0 – 15 are
signed as IN 0 – 15.

4.4.2 Signals on a Terminal Block connector

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4.4.3 Examples of input signals connection

4.4.3.1 Inductive sensor PNP type

In this example sensor with PNP type output was connected to input no. 5. In Mach3 software, we give
in this case: port=10 / pin=5.

4.4.3.2 Inductive sensor NPN type

In this example sensor with NPN type output was connected to input no. 8. In Mach3 software, we
give in this case: port=10 / pin=8.

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4.4.3.3 Common connector NC type

In this example sensor with NPN type output was connected to input no. 11 of CSMIO/IP. In this case,
in Mach3 software we give: port=10 / pin=11.

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4.5 Digital inputs connector (16-31) (CSMIO/IP-S v2)

CSMIO/IP-S controllers v2 have serial number starting with 1120… and above.

PIN number Details

1 Input 16 (+)
2 Input 18 (+)
3 Input 20 (+)
4 Input 22 (+)
5 Input 16-23 (-)
6 Input 24 (-)
Pay special attention to not exceed
7 Input 25 (-)
the permissible voltage (30VDC) on
8 Input 26 (-) the inputs lines. It may cause the
9 Input 27 (-) device damage.
10 Input 28 (-)
11 Input 29 (-)
12 Input 30 (-)
13 Input 31 (-)
14 Input 17 (+)
15 Input 19 (+)
Inputs: 16 – 31 have identical con-
16 Input 21 (+) struction as inputs: 0 -15. Look at
17 Input 23 (+) inputs: 0 – 15 description in previous
18 Input 24 (+) section, you will find there sample
connections.
19 Input 25 (+)
20 Input 26 (+)
21 Input 27 (+)
22 Input 28 (+)
23 Input 29 (+)
24 Input 30 (+)
25 Input 31 (+)

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4.6 Analog inputs/outputs connector

PIN number Details

1 Analog output 0
2 GND
3 Analog input 1
4 Analog input 2
5 10V (max. 50mA)
6 Analog output 1
7 Analog input 0
8 GND
9 Analog input 3

Analog outputs no. 0 and 1 have max. load of 100mA. Exceeding this value may
cause damage of the device.

Pay special attention not to exceed the permissible voltage (10VDC) on the inputs
lines. It may cause damage of the device.

10V output has 50mA load and serves only to supply the potentiometers, if you
want to connect the potentiometers, such as regulation of feed rate or spindle
speed correction.

Connecting analog signal from plasma generator you must remember that it
should be galvanically isolated signal!
Connecting with use of simply voltage divider do not protect against surges and
may cause controller damage.

4.6.1 Signals on a Terminal Block connector

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4.6.2 Example – connection and configuration of potentiometers

Below you can see example of connection and configuration of potentiometers for adjusting feed rate
correction and spindle revs.

As you can see on the scheme - having 10V on an analog

connector is very comfortable – thanks to it, we do not need
any external power to supply potentiometers. Potentiometer
1 was connected to analog input no. 0, and potentiometer 2
to analog input no. 1. After connection you can check it by
analog inputs preview in diagnostic window – menu „PlugIn
ControlCSMIO_IP plugin”, „Analog IO” tab.
If values on analog inputs change along with potentiometer
knob position, then the only thing left is to configure the
plugin.

Open configuration window – menu

„ConfigConfig PlugInsCONFIG”. Select
„Override Src.” tab.
We select „CSMIO-IP AIN 0” for „Feed rate
override” – so for feed rate adjustment the
POT.1 potentiometer will be used.
For „Spindle speed override” we chose
„CSMIO-IP AIN 1”, so for spindle revs ad-
justment the POT.2 potentiometer will be
responsible.
Finally we click „Save” to remember the
settings.

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4.7 Expansion modules connector

PIN number Description

1 CAN H
2 RS232 RxD
3 RS232 TxD
4 -
5 GND
6 CAN L
7 RS485 B-
8 RS485 A+
9 -

Connector serves only for CS-Lab s.c. expansion modules. Do not plug it into any others
devices, PC, etc.

4.8 Power connector

Pin number Description

1 Power – 24V DC
2 GND
3 ground

View of the plug from the

side of connecting wires

Pay special attention to not exceed the permissible power voltage (30VDC) on the input
lines. It may cause damage of the device.
If you use in the system such inductive loads as electromagnets, solenoids, electromag-
netic clutches – it is recommended to use separate 24V power supply for the men-
tioned receivers and separate for CSMIO / IP-S.

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4.9 Communication connector – Ethernet

PIN number Description

1 TX+
2 TX-
3 Rx+
4 -
5 -
6 RX-
7 -
8 -

It is recommended to use shielded cable FTP or STP cat.6.

A network interface has no Auto MDI-MDIX function. So when we connect
CSMIO/IP-S directly to a computer we should use so-called crossover cable. If you
connect it to the network switch or router - use a non-crossover cable.

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4.10 Recommended cables

Connections type Recommended cable

Digital In/out Minimum cross-section 0,25mm2 (AWG-23)

Cross-section 0,25mm2 (AWG-23)- shielded or pair of signal-

Analog In/out
to-mass wires twisted together along the entire length

Drives control (STEP/DIR) Cross-section 0,25mm2 (AWG-23)- shielded or pair of signal-

CSMIO/IP-S v1 to-mass weirs twisted together along the entire length

Cross-section 0,25mm2 (AWG-23) - shielded–twisted. You

Drives control (STEP/DIR) can possibly use the FTP computer cable. Please note that
CSMIO/IP-S v2 pairs of signals (e.g., STEP + / STEP-) you should always lead
by twisted pair of cables.

Ethernet Communication wire Standard Power cable, shielded - FTP, cat. 6.

Power Min. Cross-section 0,5mm2 (AWG-23)

If modules are installed on the same DIN rail, right next to

the controller, you can use DB9 plugs clamped on a 9-wire
CAN expansion modules
tape. If module is installed farther then you should use so
call shielded twisted pair. (FTP or STP).

During mechanical and electrical montage – particular caution is advised. Poorly tightened cable may
cause many troubles, it is also very difficult to find such a defect during launching/using the system.

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4.11 Installation examples

4.11.1 Inverter connection using an analog output.

In the example above, you can see the simplest connection of an inverter to operate spindles in an
engraving plotter.

CSMIO/IP-S outputs in use:

CSMIO/IP-S signal Connector on CSMIO/IP-S PIN numbers on Inverter function
CSMIO/IP-S (v2)
connector
Analog GND connection DB9 – Analog I/O 2 AGND – reference potential for
analog input of a speed command

Analog output 0 DB9 – Analog I/O 1 AGND – reference potential for

analog input of a speed command
CSMIO/IP digital outputs Power DB25 – Digital outputs (0-15) 17
GND

Outputs 4 and 5 power DB25 – Digital outputs (0-15) 4 24V output for controlling signals

Digital output 4 DB25 – Digital outputs (0-15) 5 Right revs switching

Digital output 5 DB25 – Digital outputs (0-15) 18 Left revs switching

Do no forget to set the configuration parameters of the inverter properly. Incorrect settings may
cause - in the best case - the inverter error, in the worst - the spindle motor becomes
permanently damaged (such damage is not covered by warranty).

Mach3 software configuration, concerning use of a spindle with revs control was described in
chapter 10 - "Mach3 Configuration".

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4.11.2 Illustrative diagram of XYZ plotter (CSMIO/IP-S v2)

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The scheme presented in this section is the simplest implementation of 3axis plotter (XYZ).

Two power supplies were used: 24V to supply the CSMIO/IP-S controller and 80V for the stepper mo-
tors drives. Switches used: normally close (NC) switches for axis homing (HOME) and limit switches
(LIMIT). In practice, it is necessary to build more complex systems, however the example above shows
the main rule.

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4.11.3 Automatic control of drives power supply (HV)

The CSMIO/IP-S controller allows for automatic control of drives power supply and eventually some
other devices. Switching on this function was described in Chapter 10th. The logic of the output opera-
tion, defined as so-called „HV Enable” is very easy. Voltage is enabled at the moment of Mach soft-
ware “Reset” request and stays “on” until one of the following conditions exist:
• FAULT signal from any axis drive
• E-Stop signal (the emergency stop mushroom pressed)
• Limit switch activation
• Loss of communication with the Mach3 software
• Error of position/speed regulators inside the CSMIO/IP-S
Here is an example of connected outputs used as „HV Enable”. The output number is irrelevant, it is
defined in the configuration window of the Mach3 software.

When you use large contactors for switching off the power, check if the coil doesn’t take more than
250mA. If so, use smaller transmitter and turn on the bigger one with it. With a large contactor it’s
good to have a diode and noise-suppression condenser to eliminate the overvoltages generated
during switching off the coil.

The „HV Enable” voltage control function is performed automatically by the CSMIO/IP-S controller.
Response time for events that cause the disconnection is less than 1ms.

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4.12 LED lights description

On the front panel of CSMIO/IP device, there are groups of LEDs that simplify verifying the correctness
of electric installation and diagnostic of such components as HOME switches, LIMIT switches and safe-
ty switches (E-Stop) etc.

4.12.1 Types and location of the LEDs

Digital inputs 16-31 LEDs and communi-

cation ports activity LEDs

Digital inputs 0-15 LEDs and error signal- Digital output 0-15 LEDs and device sta-
ization (ERRx) LEDs tus signalization (STATx) LEDs

• Digital inputs and outputs LEDs do not require more explanations. For example, if you
give the signal to the input no. 5, the IN5 LED lights up. Similarly, if you switch on the out-
put no. 2 – OUT2 LED lights up.
• CAN diode lights up when at least one expansion module is connected and when the
communication on the CAN bus is correct.
• RS485 diode lights up if there is a communication on RS485 bus.
• RS232 diode lights up if there is a communication on RS232 port.
• ETHERNET diode lights up if the controller communicates with a PC computer.
• ERR0-ERR3 diodes indicate controller errors. During normal operation, any of these di-
odes should not light up. If any of them light up you should contact service – “contact”
tab on http://www.cs-lab.eu website.
• STAT0-STAT3 diodes indicate controller status, information about the status is very help-
ful information that CS-Lab service should get if there are any problems during the device
work. Below you find detailed description of the lights meaning.

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4.12.2 State diodes description - STATx

Diodes state: STATx Description

Standby, waiting for transmission of configuration parameters from a com-
puter. It is a default state after switching power on, before communication
with Mach3 software.

Readiness state. It means that the device works correctly, there are no alarm
signals, such as E-Stop or LIMIT. CSMIO/IP-S waits for the commands from
the PC.

It means that one or more axes are currently on a manual motion mode
(JOG).

It means one or more axes homing at the moment (HOMING).

Buffering motion trajectory data.

The controller is in a G31 command mode (tool measurement sensor

touched, scanning etc).

Mode of an interpolated motion on a trajectory– CNC software or MDI

command performing. Also movement commands from the script level
(macro) of Mach3 software cause this state.

Emergency stop. It means active state appears on an input line defined as

the E-Stop or E-Stop call from the Mach3 level.

Alarm state. It appears when controller work was stopped as a result of

problems detection. This state can be caused by such situations like: FAULT
signal of servo drive, hardware limit switch signal, working area exceeded at
SOFT-LIMIT function switched on, etc.
Others. This state shows appears on case of other additional functions such
as: rigid tapping, etc.

Explanations:

 LED light is off

 LED lights continuously

 LED light flashes

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5. Recommendations and drives selection (motors drives)

Choice of appropriate motors for a machine is very individual. In this chapter, we describe briefly dif-
ferences between stepper and servomotors. Designer practice shows there is a dilemma – what solu-
tion should be chosen. Not so long ago – stepper motors were more popular in simpler machines be-
cause of high prices of servo drives. Presently, technological progress and a dissemination of servo
technology causes that building a machine – even as a hobby – it is worth to consider servo drives.

The most common mistake while decision-making is

power selection (and torque) of the servo drive. It hap-
pens because we are suggested by torque and holding
torque. The first parameter is usually given with the servo
drives and the second with the stepper motors. Both are
usually in the same unit Nm (Newton – meter). Do not
compare these parameters when you are choosing servo
drive power. Holding torque in the stepper motors is a
power that the shaft of the powered motor in standby
mode is held in position. When the revs are very low –
something about 200 rpm - the torque is almost the same (pictures below), but with increasing revs
the torque, actually the power on the motor shaft), decreases drastically. It decreases to such low
value that sometimes happens that at 1000 rpm. the motor has no power to work itself, not saying
about propelling the machine.
In the simple words: the 3Nm stepper motor, reaches 3Nm torque on very low (200 rpm.) revs, when
the revs increase its power decrease to zero. Above, on the left you can see example stepper motor
characteristic.

It is completely different in the servomotors. First, the

torque and the rev speed are nominal. Therefore, the
1Nm/ 2000 rpm motor can operate continuously with
revs: 2000 rpm. and at this speed provides 1Nm of the
torque on the shaft. Besides the servomotors have an-
other one important feature: they can be temporarily
overloaded. What does it mean? That the 1Nm motor
can temporarily deliver even 2,5-4Nm (it depends on the
type).

If we use the motion controller with fast STEP outputs like CSMIO/IP-S, the important parameter of
the motor drive is maximum frequency of the steps. Controllers with higher frequency limit of STEP
signal allow you to use higher stepper division (for the stepper motors) or encoders with larger pulses
number per rev (servo).

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However, everything has its pros and cons. So what are the disadvantages of servo drives? They are
certainly more expensive - how much, it depends what kind of stepper and servo drives you compare.
There are e.g. stepper motors controllers that cost 800 USD and there are some other that cost 40
USD (with the same power!). Generally we can conclude that the servo motor + drive package is more
expensive. Other disadvantage of the servo drives is necessity for PID controllers tuning and wiring
that is more complicated. That will be the end of the disadvantages. Great advantage of the servo
drives is that - thanks to the feedback - the servo drive indicates the overload and positioning error.
When the CSMIO/IP-S receives this signal immediately stops the axes. In the stepper motors there is
no feedback like this one, so even if one of the axis because of e.g. overload will not keep the set tra-
jectory, the machine will continue the work – breaking the same entire processed detail.
In sum – we recommend the servo drives. Their disadvantages are negligible in comparison to the
benefits they offer. Please note that the servo drive can have much lower nominal torque than holding
torque of the stepper motor. When we compare the 3Nm stepper drive and 3Nm servo drive – the
price difference may be significant. However, if we compare the 3Nm stepper drive with the 1Nm
servo drive, the price distance is not so big.
Practice shows that sometimes - mechanically identical machines are sold in two versions, with 3Nm
stepper and 1Nm servo drives. The machine with the stepper motor reaches max 7,5m/min feed rate
and 0,1g. acceleration. The machine with the servo drive reaches 20m/min feed rate and 0,4g. accel-
eration. If we add the feedback, which was mentioned before, further comparing is pointless.
The choice is in your hands of course, in some solutions the stepper motors are adequate and work
very well. Thanks to perfectly precise STEP signal timing of the CSMIO/IP-S controller the stepper mo-
tors behave much better then while controlling from e.g. the LPT port. We can use a higher stepper
division, so the motors will work quieter, smoother and they get higher revs by reducing the reso-
nance.

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6. Precise homing with encoder INDEX signal

Homing with use of so-called encoder INDEX signal is another argument for servo drives. This type of
homing is very precise even if the HOME switch has large dispersion of the trip point. In practice, hom-
ing with the INDEX allows to eliminate inaccuracy of the HOME switch.

CSMIO/IP-S is STEP/DIR type controller and does not have an encoder input. It does not mean that it is
impossible to base on INDEX. You can use built-in CSMIO/IP-S function or function of synchronization
HOME signal and INDEX in servo drive.

6.1 Solution no. 1 – Homing on “index” function

In plugin configuration window

there is a possibility to chose hom-
ing mode for each axis, with or
without index.
The configuration was described in
detail in section 10.
The solution has the advantage that
CSMIO/IP controller is able to speci-
fy a distance between home switch-
off activation on and index position
and in situation when the distance is
to small – axis homing will be
stopped. It is very comfortable and safe solution, because if index is close to Homing activation posi-
tion there may be some homing errors with even entire motor rev.

That is why, during function configuration we also give pulses number per rev and CSMIO/IP verifies
whether index is in safe distance (minn15 degrees, or so 1/24 motor revs).

According to the fact that CSMIO/IP-S has no encoder inputs, index signal is connected to standard
digital inputs of the controller. The problem is that the controller requires 24V logic signals. However
many servo drives have index output “open collector” - type and then we can handle it easily.

Do wejścia cyfrowego CSMIO/IP-S

As it is shown - pull-up resistor is enough. However sometimes we do not have “open collector” –type
output available, then the only way for homing on index is to add external, simply electronic system:

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To CSMIO/IP-S digital input

In this case, we must use directly the encoder signal or servo drive TTL encoder output. Aesthetic
connection will be in this situation a little troublesome.

Choosing servo drives we should pay attention to that they have index output “open collector” – type.
Thanks to it, we connect index signal to the CSMIO/IP controller without any problems. These output
you can find in servo drives by CS-Lab s.c. (http://www.cs-lab.eu) simDrive, servo drives by Delta
(http://www.delta.com.tw).

6.2 Solution no. 2 – Synchronization of HOME signal in servo drives.

To do the homing on INDEX this way we need the servo drive with a function of HOME signal and en-
coder index synchronization. In between offered by our company the simDrive Servo drive has this
function.

Below – the rule of connection with homing on index.

In a situation when you are choosing a servo drive and you want to see if it will be possible to do hom-
ing on index, the HOME signal synchronization should look like this:

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•HOME switch off -inactive

•HOME output of the drive - inactive
1.Homing start

•HOME switch off - activ

•HOME output of the drive - active
2. Ride on the
HOME sensor

•HOME switch off - inactiv

3. Ride off of the •HOME output of the drive - activ
HOME sensor HOME
(before the index)

•HOME switch off - inactive

•HOME output of the drive - inactive ( in this momen the CSMIO/IP-S resets the
4. Ride off of the axis position)
HOME sensor (at the
index moment)

As shown on the diagram above, the drive should extend the active state on the HOME output until it
step on the encoder index. During the tests with simDrive the achieved homing accuracy at
2000mm/min speed and encoder’s 10000imp/rev - ranged +/-1 imp. of the encoder.

That detailed homing is useful in practice, because after power failure or E-Stop pressing or any other
incident that causes that we need to re-home, we are sure that there will be no trace in a place where
the process was continued.

Homing algorithm in the CSMIO/IP-S is made in such way, that the base point does not change even
after acceleration and/or speed for the axis changed. It gives the possibility to adjust the acceleration
parameter during the process (requires a temporary stop, configuration parameters change and re-
homing).

You should note that at the moment you back off the HOME switch, the rotor should be turned for
min. 15o to the index point, because - if the index would be very close to the Home switch travel back
off point then homing dispersion may occure. In case the back off point and the index are to close, you
have to adjust the HOME switch position. Do not regulate on the encoder!

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7. LAN connection and configuration

7.1 Direct connection to PC

CSMIO/IP-S controller can be connected directly to the PC, without any switches or routers. With this
connection, you should remember to use the crossover cable. CSMIO/IP set includes the cable. Below
– how to perform the wiring.
Plug-in 1 Cable color Plug-in 2
1 white-orange 3
2 orange 6
3 white-green 1
4 blue 7
5 white-blue 8
6 green 2
7 white-brown 4
8 brown 5

For direct connection, you should set static IP address on your computer: 10.1.1.1 and mask:
255.255.255.0.

7.1.1 Windows®XP configuration.

• Click right mouse button on „My Network Places” icon and select „Properties” position
from the menu. You will see window with the icons/icon of network connections.

• Click right mouse button on the icon of a connection we want to use to communicate
with CSMIO/IP (usually it is “local connection”) – then choose „Properties”.

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• In this window – select the „Internet protocol (TCP/IP)” position and click left mouse but-
ton on the „Properties”.

• In this window enter the IP address: 10.1.1.1 and mask: 255.255.255.0. Click “OK”.
• Close the window.
• The network is now set to work with CSMIO/IP.

7.1.2 Windows® 7 configuration.

In control panel, we choose „View network status and tasks”

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Next - select „Change adapter settings”.

Click with right mouse button and select “Properties” of network connection.

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Double click on TCP/IPv4 protocol, and next enter the address IP: 10.1.1.1 and network mask:
255.255.255.0. Confirm with OK.

After CSMIO/IP- controller initialize it tries to set its IP automatically at first (it sends request to the
DHCP sever). After three failed attempts, with no response from the server- the default IP address is
set to: 10.1.1.2. It does not last longer than 10 sec. but you should remember to wait 10 sec. after
switching the power on, to let the controller communicate.

Even though the ethernet connection is highly resistant to interference - remember to use shielded
cables, especialy if you use serves or spindles with high power.

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7.2 Local network with router and DHCP.

If we plug the CSMIO/IP-S controller in to the computer network where is a router that allocates IP
addresses, the device automatically downloads the address and network mask settings.
Usually there is no need to know what IP address was assigned to the device because the plug-in and
the application that updates the controller software automatically searches the CSMIO/IP-S in the
network. However if you want to know what IP address the controller has, you can find it out from the
router’s configuration page (the controller is called CSMIO-IP-xxxx, where xxxx are the last four figures
of MAC’s hardware address). Here is an example screenshot of the DHCP server where you can see
the CSMIO/IP device in the network.

When you connect the CSMIO/IP-S controller to a network with router, you should use a non-
crossover cable (so called Straight Thru, or 1:1). The wiring way is shown below:

Plug 1 Cable color Plug 2

1 white-orange 1
2 orange 2
3 white-green 3
4 blue 4
5 white-blue 5
6 green 6
7 White-brown 7
8 brown 8

In most cases, the crossover cable attached to the device will also work, because most routers have
function of cable type auto-detect, so called AutoMDX. Do not worry. In no case, there will be no
damage, even if the router does not have the function mentioned above.

Even though the ethernet connection is highly resistant to interference - remember to use shielded
cables, especialy if you use serves or spindles with high power.

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8. Mach3 software – general information

Mach3 software of ArtSoft® Company has developed over many years and during these years, it gath-
ered many users. For relatively low price (~170USD) we get complete solution for multi-axis CNC ma-
chining. Key benefits of the software are:
• Flexibility
o Ability to create own user interfaces, transparent and suited to specific machine
applications. There is a special visual editor where you can create the Mach3 in-
terface design from the beginning or use already existing project. On the inter-
net, there are many ready solutions. Below – one of the most visually attractive
interfaces available on www.machmotion.com.

o Ability to self-extend the functionality of the software through macros, written in

simple and known by many people - VisualBasic®. It allows you to implement a
variety of measurement probes, automatic tool length measurement, automatic
storage of tools in many variants etc.
o Plug-ins support, which further extend functions of the software and allows for
cooperation with outside motion controllers. Connection with CSMIO/IP-S con-
troller is made by that plug-in, made by our company.
• Easy to use
o Those, who are already little familiar with CNC machines are able to learn all the
general functions and rules of using the Mach3 software – within one day.
o Configuration of the key parameters is transparent and intuitive, so they can be
quickly adjusted to the requirements of a specific machine.
• Dynamic analysis of the trajectory
o CNC software is analyzed in advance, so it allows for optimal adjustment of mo-
tion speed at every point of trajectory. Thus, the software is done quickly, but
with full smoothness of the motion.

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CS-Lab Company is an authorized distributor of Mach3 and Mach4 software in Poland. If you would
like to buy the license, please contact us: office@cs-lab.eu.

Please note that Mach3 software serves only to operate a machine - it is not possible to design, draw,
etc. Indeed, there are functions that allow for CNC code generation for simple operations, but it is
better to have a CAM type software, like ArtCam, MasterCam, etc.

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8.1 Recommended PC configuration

The Mach3 software does not have any unreasonable requirements about a PC computer, unless tool
paths you use take even up to tens of megabytes – then we would recommend a bit faster computer.
Even simulation of a runtime with so large paths will follow more efficiently on faster PC computer.

Recommended PC configuration:
• Processor Intel CoreDuo 2GHz
• 2GB RAM
• Graphics card 512MB

On a computer used to control a machine there should not be any other software except Windows®
and Mach3 software installed. Designing and all other tasks should be performed on other computer.
A computer used to control the machine can be connected to a computer network, but remember
about good anti-virus protection.

It is recommended to disable all visual effects in Windows® system, also a screensaver. Set power
scheme – “always on”.
If the computer is placed with the rest of control system in a control cabinet – then remember to close
the Windows® system before turning off the power. Otherwise, it may be very soon necessary to rein-
stall the operating system.

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9. Software installation
Before we begin our work, we should install the Mach3 software and plugin that ensures proper co-
operation of the software and the CSMIO/IP controller on a PC computer.

9.1 Mach3 installation

The latest version of Mach3 software you can download from ArtSoft® website:
http://www.machsupport.com/downloads.php
After the file is downloaded, you should launch it and follow the screen instructions. Generally, you
should just press the „Next” button. In the window with components to install selection – uncheck the
„Parallel Port Driver” position. It is a parallel port driver that is unused with CSMIO/IP controller.

Next, we can create a configuration profile, which we are going use. You can also create the configura-
tion profile later. If we want to do it during the installation, then – click selecting your machine type:

• Mill profile - milling machine

• Turn profile - lathe
• Plasma - plasma or gas cutter

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After you click one of the buttons, you will see a window to name
your configuration profile, e.g.:
“MyMillingMachine_400x250_CSMIO_IP”.
Avoid spaces and special signs (an underscore is allowed).

9.2 Microsoft® .Net installation (older operating systems)

If you use OS older than Windows® 7, it may be necessary to install Microsoft® .Net. This software is
available on Microsoft® website and on CS-Lab Company website: http://www.cs-lab.eu/artykul-11-
CSMIOIPS_Download.html
For proper installation, you have to be connected to the Internet. The installation is automatic, you
should only approve next steps and restart your computer when it is finished.

9.3 Installation of CSMIO/IP firmware

CSMIO/IP firmware is provided as a convenient-to-use installer. Setup proces is very fast and does not
take even a minute.

Run setup file

Click „Next” and … again „Next” – there are no reasons to modify installed components.

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Next, we can choose a path for Mach3 software and decide if it should be installed for all users. Mostly
we just leave the default settings and then double-click „Next”.

Name selection in start menu - mostly there is no need to change anything here also - click „Next” and
again „Next” when you see a summary review.

After this lasting few seconds setup another window will show up - with question if you want to launch
CSMIO/IP controller firmware that serves to controller updates. If you are not sure if you have the
latest version, you can update it now. Update process was described in B Addition.

If you do not want to update now deselect the „Launch CSMIO/IP-S Controller Firmware” option and
click „Finish”.

Mach 3 plugin and CSMIO/IP-S firmware must be the same version. Update the controller firmware if
needed. The update process is described in the addition section - „CSMIO/IP firmware updating”.

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9.4 Administrator rights in Windows® Vista and Windows® 7

It is recommended to launch Mach3 software in Win-

dows® Vista, Windows® 7 and Windows® 8 operation
systems with administrator rights.

Open „C:\Mach3” directory, find Mach3.exe file and

click right mouse button. Select “Properties” position
from the menu, and next select the „Compatibility”
tab.

Next, select the „Launch this software as administra-

tor” and click „OK”.

From now, the Mach3 software will always run with

administrator rights.

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10.Mach3 software configuration

After software installation, you should configure it all to match the settings and the controlled ma-
chine with whole its electrical system.
Elements that should be configured:
• Scale-up of each axis (namely how many pulses per millimeter/inch).
• Speed and acceleration settings for each axis.
• Assignment of in/out signals:
o Signals of homing sensors – HOME
o Signals of axis limits – LIMIT
o Signal of an emergency stop – ESTOP
o Signal of tool measurement probe/ homing etc.
o Additional inputs signals e.g. desktop buttons etc.
o Alarm signals of servo drives – FAULT
o Drives reset – DRV_RESET
o Drives voltage enabling– HV_ENABLE
o Outputs that activate spindle, cooling etc.
• Slave axis configuration (if used).
• VisualBasic® scripts configuration.
• Axis range settings for the SoftLimit function (software limits).
• Homing speed settings
• Software design customization (eventually).
Configuration is an individual matter for each machine; anyway, in the next sections you will find some
general rules.

10.1 Configuration profile creation

If during the installation you did not create a configuration profile (Chapter 9), it is worth to create it
now. In this profile will all the settings of configured machine tool be saved.

After Mach3 software installation, you should see new icons on your desktop, „Mach3 Loader” icon
among them - launch the software clicking on it. A „Session Profile” window will appear. To create a
profile click on the „Create Profile” button.

In next window, enter a profile name: e.g.

„MyMillingMachine_400x250_CSMIO_IP"
Avoid spaces and special signs (an underscore
is allowed). From the „Clone from” list select:

• Mach3Mill, if you are creating milling machine profile.

• Mach3Turn, if you are creating lathe profile.
• Plasma, if you are creating plasma or gas cutter profile.
Next click „OK” – profile was created. In the „Session Profile” window click now „Cancel” – we are
going to create a shortcut on the desktop, it will launch the Mach3 software with our configuration.
Copy the „Mach3 Loader” icon (CTRL+C, and next CTRL+V on the keyboard). Click this icon with right
mouse button and select “Properties”. On “General” tab enter any name e.g. “MyMillingMachine”, go
to the „Shortcut” tab and in the „Target element” enter:

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C:\Mach3\Mach3.exe /p MyMillingMachine_400x250_CSMIO_IP

Type the special signs „/”and „\” carefully, in correct places. You can type any other name of course
instead of "MyMillingMachine..." but it must be identical as your profile name.
After all click „OK” and now, you can launch the software using the shortcut you have just created.

10.2 The first run

Before that, you should connect Ethernet cable

of the controller to a computer or plug it into a
computer network. You must switch the con-
troller power ON at least 10 seconds earlier.
After you launch the software for the first time,
you will see the window of license approval.
You should fill in the check box and agree by
clicking the button as shown in the picture.

If plugin for CSMIO/IP-S was installed properly, as described in the chapter 9 - then there should this
window appear:

Select motion controller type –

„CSMIO_IP/P” and fill in the check
box: „Don’t ask me again”, so
Mach3 in this configuration profile
will always use CSMIO/IP-S control-
ler. Confirm your selection with
“OK”.

Before you start other parameters configuration, you can verify if communication with the controller
is correct. Click on the „Plugin Control” top menu and select the „ CSMIO_IPplugin” position.

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You will see CSMIO/IP diagnostic window. If the "Con-

nection status” light is green it means that the firm-
ware was installed correctly and communication be-
tween Mach3 software CSMIO/IP controller is also
correct.

If during Mach3 software launching the „CSMIO/IP connection” window will

appear and the „Connection status” light in the diagnostic window will flash
red, it means that the CSMIO/IP-S was not found in the network. In that
case, check some possible reasons:

• The Ethernet cable must be connected to the device before turning the power on. If it
was not – quit the Mach3 software and turn the CSMIO/IP-S power off, connect the
Ethernet cable, wait 10 seconds and launch the Mach3 software again.
• If CSMIO/IP-S is connected directly to PC, verify if network settings are correct – de-
scribed in chapter 7. Quit Mach3 software, verify the settings and change if necessary,
start the software again.
• If at least 10 seconds have not passed from turning on the device power to Mach3
launching –quit the software and launch it again.
• You can try to use a different network cable.

If these tips did not help and there is still no connection, you should contact your distributor or the CS-
Lab company.

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10.3 Configuration of axes used in a machine

At the beginning, you should activate support of the

axes you are going to use. Select the
menu position „ConfigPorts and Pins” and next „Mo-
tor Outputs” tab.
Select axes we are using by clicking „Enabled” - the
green ticks will appear next to them. We do not acti-
vate slave axes in that window.

• Example 1: 3 axis plotter X, Y, Z.

o Activate the X, Y, Z-axes.
• Example 2: 3 axis plotter + rotary A axis, Y-axis on two drives (slave axis).
o Activate the X, Y, Z, A axes (the slave axis should not be activated here).

In „Motor Outputs” tab if you use Mach3 software and CSMIO/IP controller following options are
unused: Step Pin, Dir Pin, Dir Low Active (you change directions in menu „ConfigHoming/Limits”),
Step Port and Dir Port.

By default axes are assigned to the following

STEP/DIR channels: X[0] / Y[1] / etc.
Pin numbers entered in Mach3, in „Port&Pins”
window, „Motor Outputs” tab do not matter. To
assign other STEP/DIR channels to the axes you
should do it in plugin’s configuration: menu
„ConfigConfig PlugInsCONFIG”.

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10.4 Configuration of digital input signals

Configuration of the input signals we call from

menu „ConfigPorts and Pins”, by selecting „In-
put Signals” tab. A list of standard input signals
will appear and you can assign these signals to
hardware inputs of CSMIO/IP-S controller.

Columns explanation:
Column name Description
Enabled • Green tick means we are using the signal.
• Red X cross means that we are not interested in that signal and it
should not be used
Port # Input port number – for CSMIO/IP it is always port no. 10.
Pin Number Pin number, means the CSMIO/IP input number, e.g. input no. 14 of the
controller we put here as a pin no. 14.
It does not mean a pin number on CSMIO/IP connector.
Active Low Signal polarization change, it is a selection whether the signal should be
active at 0V or at 24V.
Emulated Signal emulation with keyboard shortcut. In CSMIO/IP-S controller, only
some signals may be emulated: „THC On”, „THC Up”, „THC Dn” and
„Probe”.
HotKey Keyboard shortcut for signal emulation.

Detailed description of the signals is available in ArtSoft® documentation: www.machsupport.com,

below we present short description of the most important.

Signal signature Description

X++, Y++, Z++, A++, B++, C++ Hardware signals of positive limits. A machine stops immediately
when one of the signals becomes active.
X--, Y--, Z--, A--, B--, C-- Hardware signals of negative limits. A machine stops immediately
when one of the signals becomes active.
X Home, Y Home, Z Home, Signals of axis homing.
A Home, B Home, C Home
INPUT1 – INPUT4 Input signals for general use. They can be used e.g. in VisualBasic®
scripts.
Probe Signals of a measurement probe, e.g. sensor of tool length meas-
urement sensor.
Index Index from a spindle for rotational/threading speed measurement.
Limit Ovrd Motion forcing, if one of LIMIT signals is active. It is useful to allow
for move back off the limit switch. If we are using Auto Limit Over-
ride function – this signal is useless.
EStop Emergency stop. You should pay special attention to set this signal
correctly and test how it is functioning.
THC On For plasma cutters. During plasma cutting a machine stops automat-

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ically, when this signal becomes inactive.

THC Up For plasma cutters. Signal of automatic torch high control, an active
state causes Z-axis raising.
THC Down For plasma cutters. Signal of automatic torch high control, an active
state causes Z-axis lowering.
OEM Trig 1-15 Using these signals, you can e.g. start software with a button on a
machines desktop.
JOG X++, JOG Y++, JOG Z++, Signals that allow for motion of each axis in manual mode (move-
JOG A++ ment in the positive direction).
JOG X--, JOG Y--, JOG Z--, JOG Signals that allow for motion of each axis in manual mode (move-
A-- ment in the negative direction).

If you are not sure on which input in the CSMIO/IP-S is one of

the signals connected, then you can open diagnostic window
from the „Plugin Control/CSMIO_IP_P_plugin” menu, go to the
„Digital IO” tab and in the „Digital inputs” area there is a pre-
view of all inputs state of our controller. Then you can just e.g.
pressing a limit switch manually to look at a screen, and see,
which input changed its state. You can also watch the LEDs
located on the controller.

After all input signals configuration it is worth to

check, whether it has been done correctly. To do so,
close the configuration window, approving with „OK”
and then go to the „Diagnostics” screen (top button
bar in Mach3 software window).
Under the „Input Signals current State”, there are
controls, which show current state of input signals of
the Mach3 software. Now you can press the emer-
gency stop button, the „Emergency” LED should start
flashing. The same way you can check other signals,
e.g. by pressing manually the limit and homing
switches etc.

Check carefully the E-STOP signal functioning before you continue your configuration. It is very im-
portant to have possibility to stop the machine immediately, especially during the first run and config-
uration!

In the CSMIO/IP controller, there was additionally implemented fault signals support from servo
drives. Details in the „Additional configuration functions” chapter.

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Since the CSMIO/IP v1.07 firmware version

there is a possibility to give the same input
PIN as LIMIT and HOME. You should disa-
ble the „Home Sw. Safety” option in „Gen-
eral Config” window of Mach3 software.
With „Home Sw. Safety” option disabled,
the LIMIT signals are not monitored during
homing.

10.5 Configuration of digital output signals

Digital outputs are used for such tasks as e.g. spin-
dle/torch activation, activation/releasing brakes of elec-
tromagnetic motors, cooling, solenoids valves activation,
etc.
The outputs configuration is almost the same as the
inputs configuration.

Columns explanation:
Name of the column Description
Enabled • Green tick means we use the signal.
• Red X cross means that we do not use the signal and that it should
not be used.
Port # Input port number – for the CSMIO/IP-S it is always port no. 10.
Pin Number Pin number, means the CSMIO/IP-S output number, e.g. output no. 5 of
the controller we put here as pin no. 5.
You do not give here PIN number on CSMIO/IP connector.
Active Low Signal polarization change, it is a selection whether the signal should be
active at 0V or at 24V.

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Detailed description of the signals is available in ArtSoft® documentation: www.machsupport.com,

below we present short description of the most important.

Signal signature Description

ENABLE1-6 Signals of axis enabling. Can be used e.g. as an enabling signals (Ser-
vo ON) in servo drives. For axes in use (section 10.3), the signals
pass into active state after pressing RESET on Mach3 screen. If Mach
goes into stop state, the signals are disabled.
OUTPUT1-20 Universal outputs. Can be used to control a spindle, cooling as well
as from VisualBasic scripts level.
Current Hi/Low Current limit output for stepper motors. If axes of a machine are in
standby mode, there is no need to supply the stepper motors with
full current. This signal becomes active, when axes are not moving.
Current limit allow for energy consumption reducing and motors
heating up – the same lengthening their life. Unfortunately, many
controllers of the stepper motors do not have correct input to con-
nect this signal.

Again, during system startup the diagnostic window from the

“PlugIn Control” menu may be helpful. In „Digital IO” tab, you
can view current output signals state and assess if any prob-
lems result from some wrong configuration or from some in-
correct electrical connection.

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10.6 Configuration of spindle and cooling

First, you must configure output signals. For that you

should select „Config/Ports and Pins” from menu
and go to „Spindle setup” tab. In „Relay control”
group set Mach3 output signals numbers (these are
not the numbers of CSMIO/IP outputs, see previous
section about output signals configuration). Here you
can select the OUTPUT1-6 signals.

There are two options: for right revs (M3) and left revs (M4). We must uncheck „Disable Spindle Re-
lays” box of course - that means no support for spindle activation.

In „Flood Mist Control” group placed below, we set control of cooling activation just the same way.
Here you can also take the OUTPUT1-6 signals. If we want to use the control function of cooling activa-
tion, we must deselect the „Disable Flood/Mist Relays” box. There are two possible modes of cooling:
water mist (M7) and water stream (M8). For each mode, we give the right output signal. You can also
give the same signal for both modes, so then it will be activated with both the M7 and M8 command
from the G-Code. Additionally in the „Delay” area, you can also set the delay you want after cooling
activation before machining begins.

Time delay for spindle switching on and off is also an important parameter. In particular, the high-revs
spindles need a little time after activation to speed up to the required speed. In the „General Parame-
ters” group, we can define independently an acceleration and deceleration time for right and left revs.

CW Delay Spin UP Acceleration time for right revs

CCW Delay Spin UP Acceleration time for left revs
CW Delay Spin DOWN Deceleration time for right revs
CCW Delay Spin DOWN Deceleration time for left revs

10.6.1 Analog output configuration

The last things we configure in the „Ports and Pins” window are parameters related to the control of a
rotational speed through the digital input of CSMIO/IP-S. In the „ModBus Spindle – use step/dir as
well” group select the „Enabled” area, in the „Reg” box enter value of 64, and in the „Max ADC count”
– 4095. Now you can close the „Port and Pins” configuration window, click „Apply” and „OK.”

For correct control of the revs, you have to specify what range of the
revs our spindle has (including the inverter settings and eventual pul-
leys). Select the „Config/Spindle Pulleys...” menu position. If we use
one ratio then enter „Min” and „Max” revs. Approve with „OK.”

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Last thing related to the revs control is a choice of

analog output, which will be used.
• select from the menu „Config/Config
PlugIns”
• click „CONFIG” next to the „CSMIO/IP”
• go to „Spindle” tab, in the „Spindle DAC”
group
• select „Enable”
• on the „Select Analog Output” list select an-
alog output.

Again, during the startup the diagnostic window may be helpful.

In the „Analog IO” tab, you can preview current voltages on
analog inputs and outputs. When we configure the spindle,
then in a MDI tab you can enter e.g. M3 (enter), S2000 (enter).
It should cause spindle activation (right revs) and setting the
revs on: 2000 rpm. In the diagnostic window, you can see digital
outputs and voltage on analog output activated.
Additionally the icon informs us which analog input is config-
ured to control a spindle.

Check carefully inverter settings before spindle activation, incorrect configuration may cause perma-
nent damage of the spindle, which is not covered by warranty.
Pay attention if the left/right revs are activated correctly – machining with incorrect revs direction may
cause damage of a tool or a work piece.

10.6.2 Problematic PWM Control function

A frequent reason of problems with analog inputs is „PWM Control” option set in Mach3. On first
sight, sometimes we do not see this position is marked, especially when „Use Spindle Motor Output”
position is not active. Below you can see correct and incorrect settings.

If „PWM Control” is check-marked but inactive you must first mark “Use Spindle Motor Output”, then
click „Step/Dir Motor”, and again uncheck the „Use Spindle Motor Output”. Selecting „Step/Dir Mo-
tor” in this place does not mean that spindle will be controlled by STEP/DIR signals. Configuration of a
spindle as an axis you will perform in plugin. It is described later in this guide, chapter: “Additional
configuration functions in plugin’s window”.

The „PWM Control” option should be unchecked because it is incompatible with CSMIO/IP and leads
to errors during spindle revs control.

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10.7 Configuration of resolution, speed and acceleration

Before we start working, it is absolutely necessary to set

resolution (so-called scaling) of axes correctly and to set
their max. speed and acceleration -in the Mach3 soft-
ware - „Config/Motor Tuning” menu. In the window,
first select an axis you want to configure, next enter
parameters and click „SAVE AXIS SETTINGS”. Now you
can select and set the next axis.

If we forget to click on „SAVE AXIS SETTINGS” all the changes will not be saved.

For correct axis scaling you must know how many steps falls on a unit (millimeter, inch or degree). To
understand how to calculate it, look at the example below:
• A linear axis is powered by servomotor with 10000 rpm encoder.
• A servo drive is configured without a multiplier and a pulley, so the 10000 STEP pulses cause
a 1 rev of the motor.
• To transfer the drive there was a ball screw used - pitch 10mm.
• No ratio between motor and a screw.

𝑠𝑡𝑒𝑝𝑠 𝑛𝑢𝑚𝑏𝑒𝑟 𝑝𝑒𝑟 𝑚𝑜𝑡𝑜𝑟 𝑟𝑒𝑣

𝑆𝑡𝑒𝑝𝑠𝑃𝑒𝑟 =
𝑓𝑒𝑒𝑑 𝑝𝑒𝑟 𝑚𝑜𝑡𝑜𝑟 𝑟𝑒𝑣

So there are 10000 pulses per motor rev and 10mm feed rate. Dividing these values 10000p/10mm
we get 1000p/mm value, which we enter into „Steps Per” box in configuration window.

In „Velocity” area, we set an axis speed. If we are using millimeters as an unit then speed is shown in
mm/min, if we use degrees - degree/min, if inch - inch/min. Max. speed value is very individual and
depends on what motors, drives etc. were used. For the first tests, we recommend to enter relatively
small value e.g. 2000mm/min, in case something went wrong, we will always have enough time to
press an emergency button E-STOP.

In „Acceleration” area, we define acceleration for an axis. At the beginning, we recommend to enter
something about 400mm/s2. Later you can set this parameter experimentally by assessing the ma-
chine working.

Remember to click „SAVE AXIS SETTINGS” for each axis after finished edition. Perform the configura-
tion as follows:
Open „Motor Tuning” window Select axis („Axis Selection”) Enter the parameters”SAVE AXIS
SETTINGS”Select the next axisetc. Click „OK” and close the window.

„Step pulse” and „dir pulse” areas do not matter for CSMIO/IP. They are used to control via LPT port
and they define width and STEP/DIR pulse time. The CSMIO/IP-S controller provides the signal with the
50% duty cycle, which is the most optimal variant.

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Due to connection of STEP/DIR signals to the drive (both servo and stepper drives) pay attention which
STEP edge is active.

The example:
While connecting the controller– e.g. for the M542 stepper motor you should connect the PUL+ signal
to STEP+ and PUL- output to STEP signal of CSMIO/IP. This way – switching on the optocoupler in the
M542 will be followed at proper edge of the CSMIO/IP-S STEP signal. If the connection is incorrect, 1
step will be lost during every direction change. After a long work, it may accumulate large position
error.

If needed (e.g. if there are position errors) STEP signal polarization may be changed by software, indi-
vidually for each axis It is set in menu „ConfigPorts and Pins”, „Motor Outputs” tab, „Step Low Ac-
tive” column.

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10.8 Configuration of directions, homing and software limits.

When axes are scaled and their speed is config-

ured, it is important to set directions correctly.
Useful function is possibility to indicate software
limits - the machine working range.

Select in the menu „ConfigHoming/Limits” posi-

tion. In the window, we have configuration param-
eters for each axis:

Column name Description

Reversed Switching this field, you change direction of an axis motion.
Soft Max Maximum range of motion in positive direction
Soft Min Maximum range of motion in negative direction
Slow Zone In the CSMIO/IP-S, this field is not used. In LPT, it is used to define a section
for braking near to the end of working range. CSMIO/IP-S controller auto-
matically calculates the braking distance including acceleration defined for
the axis. The best way is to enter 0 in this box.
Home Off. Starting v1.07 version firmware - in this field we can define a distance of
going off from HOME sensor after homing. If we enter e.g. 5mm, then the
controller will home the axis on a HOME sensor and after that, it will go off
with 5mm and reset axis position. You can also enter a negative value - in
some cases it us very useful.
Home Neg As a standard an axis homing goes into negative direction. However, we
usually home the Z-axis upwards and the down motion is a negative direc-
tion. Therefore, we have to do Z-axis homing in a positive direction. Home
Neg is to select homing direction.
Auto Zero This area is not used on the CSMIO/IP-S controller. After homing – the axis is
always zeroed.
Speed % Homing speed. It is shown as a percent of maximum speed defined in „Mo-
tor Tuning”. For the first tests we recommend 10%.

Attention! – you can enable and disable software limits. If they are enable, the software cannot con-
trol an overrun of working area. The only protections are hardware LIMIT switches.

When software limits option is active („Soft

Limit” on a Mach3 main screen), the
CSMIO/IP-S controller does not let for any
move if axes of a machine are not homed.
Current status of the function is shown by the
green light around „Soft Limit” button.

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10.9 Configuration functions in a plug-in window

The configuration window of plugin is activated by „ConfigConfig Plugins” menu position, click
„CONFIG” next to the CSMIO/IP name.
If there were different types of CSMIO/IP controllers installed then click “Config” next to the controller
that will be used.

10.9.1 Axes special functions

Axis configuration is divided into the

following groups:
• Servo Alarm Input
• Channels Selection
• Index Homing
• PID Regulator
• Slave Axis Configuration

10.9.1.1 Servo Alarm Input - an alarm input in servo drives

The CSMIO/IP- controller has a possibility of autonomous reaction to fault signals from servo drives. A
drive may generate a fault e.g. in case of overload. If the fault signal appears the CSMIO/IP stops all
axis within 0,1ms. It is worth to configure in servo drives a dynamic brake function, which will reduce
distance that an axis moves with the power of inertia.

Enabled Function enable/disable

Low Active Active signal in a Low state
Pin Input number on CSMIO/IP-S controller

10.9.1.2 STEP/DIR Channels Selection

CSMIO/IP-S controller has 6 STEP/DIR output channels. For X axis, by default, there is assigned 0 chan-
nel, for Y – 1 channel, Z – 2 channel… etc.
For each axis there can be any channel assigned. We made the choice from the „STEP/DIR Output
Channel” list.

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10.9.1.3 Index Homing

If we connected INDEX signal from servo drive to the controller, then we can enable precise homing
function with INDEX signal use. It greatly improves homing repeatability, even when homing switches
have quite large spread.

Enabled Turning function on and off

Pin CSMIO/IP input number
Encoder Pulses/Rev Pulses number per encoder rev (with all edges)

10.9.1.4 A PID controller

This group is only for CSMIO/IP-A controller. In IP-S model is not active.

10.9.1.5 Slave Axis configuration.

In large machines there are often two motors used to support single axis – one on each side. Even
though in Mach3 software - „Config” menu there is a position to configure slave axes, we provide here
autonomous support for the function, to increase reliability level.
Some users implement a slave axis by linking the STEP/Dir signals of two drives and connecting them
to one channel of a controller or they use the slave axis function, which is available in some servo
drives.
The slave axis implementation through the CSMIO/IP-S has one significant advantage –function of
machine geometry correction available (e.g. gantry perpendicularity). It is more specifically described
in the addition „Slave axis configuration example”. In brief – for each X, Y, Z-axis you can define one
slave axis. The slave axes can be A, B and C.
Configuration parameters:

Slave Axis selection, which one will be slave for the currently selected
one
Mode Slave axis working mode
Geometry Correction Geometry correction value of a machine tool

Slave axis working mode:

No Correction Mode without correction – Master and Slave axes work just
like “glued” together.
Read Difference Homing position difference readout between Master and
Slave axes. After homing, the value will be entered in „Ge-
ometry Correction” area.
Sl. Correction After homing, Slave axis is “freed” for a while and geometry
correction motion is done. It allows for e.g. perpendicularity
settings in gentry machines.

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In „A” addition you can find slave axis configuration example described.
If you want to use slave axis function – read the addition „Slave axis configuration example”.

CS-Lab Company has made every effort to ensure reliability of the CSMIO/IP-S controller. However,
the company does not take any responsibility for any mechanics damage because of wrong configura-
tion and any eventual failure or errors of CSMIO/IP-S controller.

We strongly discourage using slave axis function with stepper motors. Stepper motors don’t have
feedback and it’s easy to damage mechanics in a machine, e.g. when one of the motors brakes and
the other one still works.

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10.9.2 Spindle configuration

CSMIO/IP controller has many additional functions according to a spindle. The options were divided
into following groups:

Spindle DAC Selection of analog output for spindle revs control

Spindle Encoder CSMIO-ENC module configuration
(CSMIO_ENC)
Spindle Alarm Input Spindle drive alarm signal input configuration
Spindle Axis Spindle operation through axis channel (STEP/DIR) options

10.9.2.1 Spindle DAC – revs control output

Enabled Enabling revs control on analog 0-10V output
Select Analog Output Analog output selection

10.9.2.2 Spindle Encoder – spindle encoder module

P/Rev Pulses number per spindle rev (with all edges)
Inv. Direction Analog output number selection

10.9.2.3 Spindle Axis – axis channel spindle control

Enable Spindle Axis Function enable
Reversed Direction Revs direction change
Channel Selection STEP/DIR output channel selection for spindle operation (it's important to re-
member that for “common” axis operation there are only 5 channels left so it's
impossible to use 6 axes)
PID Regulator Only for CSMIO/IP-A – PID regulator tuning
Align at stop Automatic spindle setting in demanded angle always after turning off. This
function is especially useful when spindle axis, for tool change, must be set in
a defined position. „Enabled” activates the function and below you can enter
the angle for spindle setting.
Speed/Accel Config Configuration of pulses per spindle drive motor rev and acceleration. The
acceleration value entered here is a time in which the spindle gets max. revs
(defined in Spindle Pulleys).

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10.9.3 Override sources – feed speed and spindle revs corrections source selection

Mach3 software allows for feed speed and spindle

speed change during work. As a standard, it is ad-
justed using two sliders and a main screen. If ma-
chine tool were equipped with additional panel
with buttons, it would be easier to adjust the
speed using knobs placed on it. With CSMIO/IP-S,
we can also control feed speed and spindle revs
using potentiometers connected to analog inputs.

In „Override sources” tab you can set whether the speed

adjustment should be done through Mach3 screen, analog
inputs or additional MPG encoder axes, etc.
„Feed rate override” applies to feed speed and „Spindle
speed override” to spindle revs.

The following options are available:

Mach Regulation via PC (slider on a Mach’s screen)
CSMIO/IP AIN 0/1/2/3 Analog inputs of CSMIO/IP controller
MPG AIN 0/1 Analog inputs of CSMIO-MPG module
MPG AXIS 4/5/6 4, 5 or 6 axis of MPG encoder jog (pendant)

For both feed speed and spindle revs speed control we can define digital input of CSMIO/IP, which will
force control from Mach3 screen – „Forced Mach override”. Thanks to this, you can easily and quickly
switch the source of speed defining– e.g. using a switcher placed on a machine’s panel.

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10.9.4 Plasma – additional functions for plasma cutters

In current software version, we have one op-
tion available – torch high control via analog
input.
Configuration is only about to enable the func-
tion, select polarization, and to select analog
input.
The function, with normal polarization, works
the way that for 0V on analog input there is
correction entered in THC min, and for 10V -
THC max configured in Mach3 screen. With
reversed polarization – for 0V there is THC max,
and for 10V - THC min.

Enabled Function enable/disable

Inversed Polarity Polarization reverse
Select input Selection of analog input for torch high control

Attention! – Plasma generators are dangerous because of high voltage on electrodes. To analog inputs
of CSMIO/IP you should connect only galvanically isolated signal and well filtered (it is good to place
RC filter in the connector). Incompetent connection of signals of a plasma generator to CSMIO/IP con-
troller may cause its damage.

10.9.5 Misc IO – Special functions related to I/O

10.9.5.1 Servo drive RESET

Any CSMIO/IP controller output can be as-
signed as a RESET signal for servo drives. On
the output, there will be a short pulse every
time when in Mach3 the RESET function will be
called.

10.9.5.2 HV Enable
In this place you can – for any CSMIO/IP controller output – assign a function of main voltage activa-
tion (e.g. for servo drives). In many alarm situations like e.g. E-STOP signal activation, additionally main
supply disconnection it may increase security level.
Output defined as „HV Enable” will be active during normal work of CSMIO/IP controller, in case of any
alarm situations such as limit switch or E-Stop touch, the signal will become inactive.

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10.9.5.3 Input signals filter

Sometimes happens that on a large machine tool, electromagnetic noises level is so high that standard
hardware limits, mounted in CSMIO/IP are not enough and so there appear false signals e.g. LIMIT, E-
STOP etc., causing machine work brake.
In such situations, the input signals filtering function may be very helpful. We define here filtering
time. I do not recommend using high values because of the fact that later there may some delays oc-
cur in reaction to digital inputs.
If values of 1-15 (4ms – 60ms) do not solve the problem, then a hardware and machine tool wiring
quality may be the cause.

Long filtration time may delay reaction on alarm signals even up to 0,4s. The delay will also be visible
during HOMING or tool measurement (PROBING), causing that machine’s axis will go through a longer
distance after sensor activation.
As mentioned above, there is rather no sense to give filtration time higher than 60ms, and so small
delays are practically unnoticeable.

10.9.6 Other plugin functions

10.9.6.1 MPG multipliers

If you use CSMIO-MPG module and an external
jog encoder (handwheel), you can switch the
multiplier between three values. In this place,
we can select what values it will be. Lower
range gives better precision and safeness – be-
cause in this case turning the encoder we will
not speed up the machine to high speeds.
Higher range will be better for large-size plot-
ters to move the axes quickly over long distanc-
es.

10.9.6.2 Axes DeRef & Zero – axis reset after emergency stop
CSMIO/IP-S and CSMIO/IP-M controllers reset axis position by default and require reference after
emergency stop. This solution is safe because often, after emergency stop, real machine’s axis position
is unknown. Position and reference reset gives a clear information to operator to do homing again, to
check material position etc. However sometimes automatic reset may be burdensome or in some
cases even not recommended. Deselecting „Set Axes to ‘0’ on RESET option, we can disable automatic
position resetting.

10.9.6.3 E-STOP requests – alarm events

In this place, we can disable machine stopping in following situations:
• Digital outputs overload
• CANOpen Timeout
Deselecting this option causes that such situation will not cause that machine stops.

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10.9.6.4 Safety Extras

In CSMIO/IP firmware few additional functions were implemented, which increase safety and comfort
of work.

Auto Z-Inh Enable Automatic Z-axis move limitation. Enables protection against
worktable of a machine damage. More details in chapter
14.1 – Automatic Tool Length Measurement.
Smart Limits Movement blocking when hardware limit signal is active. It
works the way that e.g. when X++ signal is active, then we
can move X-axis only in „-„ direction.
Probe protection Tool length sensor protection. When Probe signal is active
then Z-axis manual jog in „-„ (down) direction is blocked.
If Probe signal goes active during treatment, a machine will
be stopped just like in situation when E-Stop is pressed on.

10.9.6.5 CSMIO Connection Properties – additional connection options

Default MAC Default MAC address for a connection. It is useful if in our

local network, there are few CSMIO/IP controllers and we do
not want to select a controller we want to connect with at
every Mach3 start. It is set by „Set as Default” button and
reset using „Clear Default”.
Connected MAC Information about MAC address of currently connected
CSMIO/IP controller.
Name Currently connected controller name. You can name it by
yourself. The name will also be displayed in controller's se-
lection window if in local network there is more than one
CSMIO/IP controller. To give your name you must enter it
and click „Change Name”.
Clear Default Default MAC address deletion.
Set as Default Default MAC address setting.
Change Name Private name setting for connected CSMIO/IP controller. It
can be any name. However, it cannot contain spaces or spe-
cial characters - e.g. „Lathe01”.

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10.10 Selection of inch/mm units

Selection of units by which the axes in „Motor Tuning” are scaled is set in
„ConfigSelect Native Units” menu position. Select unit in the window and close
„OK”. Selection of units for a treatment is done by G20 (inch) and G21 (mm) com-
mands.

10.11 Some parameters in the General Config window.

In the „ConfigGeneral Config” menu, you find basic configuration parameters of Mach3. Many of
them do not need any modifications, but it is worth to change some of them. In the picture below, you
can see a table with the most important parameters and a short description of each one.

Parameter/group Description
name
Tool Change Configuration of an automatic tool changer. An important issue: even if we do not
have an automatic tool changer but we use a tool measurement sensor - the Auto
Tool Changer should be selected. Otherwise, Mach3 will not take tool length into
account.
Angular Properties Checking the box, we select, if A, B, or C axis works as angular. Unchecked box means
that the axis works as linear.
Pgm end or M30 or It is about behavior at the end of a program, M30 or REWIND command.
Rewind
Motion Mode Motion mode selection: Constant Velocity or stop at every trajectory section (Exact
Stop). The Exact Stop mode may be more precise in some cases but much more slow-
ly. Constant Velocity mode is used in 99% of cases.
IJ Mode Data format for circular interpolation. Usually "Inc" should be selected. After loading
the trajectory, generated with CAM software, if there are problems with circular
interpolation (like large circles in a 3D preview), you can try to switch to „Absolute”
and then load G-Code again.

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Active Plane of Default plane for circular interpolation G2/G3. Usually X-Y for milling machines, X-Z
Movement for lathes.
Jog increments In Default feed values for stepper work.
cycle mode
Home Sw. Safety Homing mode. When this mode is disabled, the homing process is less restrictive. It
allows for e.g. homing start when an axis is already on the HOME switch. When hom-
ing also LIMIT signals are not taken into account.
With this option selected so-called safe homing is performed, LIMITs are all the time
taken into account, also you cannot start homing when an axis is on a HOME sensor.
Ignore M calls while Macros ignoring („M” commands) from g-code file when loading. This option should
loading be activated. Without it when file is loading, a machine may start performing macros
by itself.
Look Ahead Mach3 performs dynamic trajectory analysis in advance, to adjust motion speed in
every trajectory place. In the „Look Ahead” area, you can enter number of G-Code
lines, which should be analyzed in advance. Usually 1000 value is enough to get mo-
tion smoothness even when dynamic and fast softwares are made.
Run Macro Pump When this option is selected in a catalogue with VisualBasic scripts you can create a
macropump.m1s file, it contains macro, which will be called cyclically several times
per second.
Home slave with The intention of Mach3 authors is an option, which enable/disable slave axis and
master axis master axis homing together. In CSMIO/IP-S controller, a slave axis is always homed
with master axis.
G04 Dwell in ms With this option selected a delay parameter for G04 is counted in milliseconds. It is
useful when you need precise, short time delay e.g. in plasma cutters.
Use watchdogs Do not use – this function should theoretically „watch” various modules of the soft-
ware and in case it should switch an emergency STOP. In practice, it does not work
properly and may cause problems. In CSMIO/IP-S software, there are special algo-
rithms, which autonomously monitor communication and whole control system
work.
CV Control Parameters for a Constant Velocity work mode. By default, all fields should be unse-
lected. However sometimes CV settings modification is necessary. E.g. if machine
acceleration is low and treatment goes with high speeds then CV mode may cause
that path corners will be rounded. We can set CV mode toleration by selecting „CV
Dist Tolerance” option and entering max. deviation from demanded shape.
Rotational Parameters in this group relate to angular axes (rotary).
„Rot 360 rollover” determines if there should be rollover after crossing 360 degrees.
„Ang short rot. On G0” causes that at inverted G0 move, a rev may be shortened. So
O O
when an axis has at the moment e.g. 320 and should go to 0 , it will not go back
O O
with 320 but it go right with 40 .
„Rotational soft limit” parameter determines if for rotary axes soft limit switches
should be taken into account.
Enhanced pulsing This parameter does not matter with CSMIO/IP-S.
Screen control In this group, selection of „Hi-Res screens” and „Auto screen enlarge” parameters
causes Mach3 screen enlarges to fit its size to screen resolution. However very often
an interface is in effect disproportionately stretched and it is better to disable the
functions mentioned above.

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11.First tests

11.1 Checking the input signals

Before starting the tests in motion, you should

first verify the main input signals, such as:
• Homing sensors – HOME
• Limit switches – LIMIT
• Emergency stop – ESTOP

After running Mach3, go to „Diagnostics” tab.

In „Input signals current state” area there are
shown light indicators of the input signals. Dur-
ing the test, any of axes should not be on a
limit switch or homing sensor. You should
manually, sequentially activate the HOME sensors and verify if correct indicators light up. There are
axes at the input signals indicators marked as M1, M2, M3, M4, M5, M6 what corresponds in order to
X, Y, Z, A, B, C. After HOME switches verifying you should check LIMIT switches. Again - manually acti-
vate the LIMITs on each axis and check on a screen, if correct indicators light up. If the light indicators
or indicator light up constantly and they turn off after manual LIMIT switch deactivation - it means
wrong polarization – you must change configuration in „Ports and pins” window (see previous sec-
tions).
If on all axes the HOME and LIMIT sensors work fine, it is time to verify an emergency stop signal (here
Emergency) again. After the E-Stop pressing – the indicator should flash red light. When you release it
- it should turn off.
If everything works correctly, press RESET on the screen and go to the next section.

If there is no response for any signals, you should check if software

communicates with the CSMIO/IP-S controller correctly. In the diag-
nostics window (in „PlugIn ControlCSMIO_IP_Plugin” menu) you
can check the connection status. If the control light is red, you can
try to quit and run Mach3 again. If it does not help see again the
sections about configuration and installation.

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11.2 Verification of axes scaling and motion directions

First motion control should be made at low speed. After pressing Tab key on a
keyboard – manual feed rate panel should open. In „Slow Jog Rate” enter e.g.
10%. It means that the motion will have 10% of maximum speed, defined in Mo-
tor Tuning.
SoftLimit switches should be disabled for these tests. Find the button on
Mach3 main screen – if there is a green light around it, then click this button to
switch it off. If necessary press on the main screen, Mach3 software will
be in standby mode. There should be green light around the button.
You can control XY-axes by arrow keys on a keyboard, Z-axis by „Page Down” and
„Page Up”. You can also use the buttons from manual feed rate window.
You should check each axis if:
• Motion direction is changing. If not, it may mean incorrect connec-
tion of DIR Signal to a drive.
• Directions are not changed. If so, you should change an axis direc-
tion in „ConfigHoming/Limits” menu.

When all axes have their motion directions configured correctly – you can specify homing directions
(sides). For 3-axis machine XYZ - most common configuration is homing of XY-axes in negative direc-
tion and Z- axis in positive direction. In „Config/Home/Limits” for Z axis there should be „Home Neg”
selected.
Before further tests, you should check axes scaling. The best is to use dial gauge or other precise
measurement tool.
In manual feed rate panel set the Jog Mode and 1mm step size. „Slow Jog
Rate” does not apply to motion in positional mode (step motion) so speed
is set on the main screen in „Feedrate” area. For this test, you should
enter low value e.g. 100mm/min. Now, after pressing e.g. right arrow on
the keyboard the X-axis goes 1mm right. You should go this way at least 10mm
(each axis), verifying with dial gauge the distance actually made by the axis. The dial
gauge should be reset after 1mm. If you see clear difference between the positions
(requested and actual), it means that that the „Steps Per” parameter in the Motor
Tuning window is set incorrectly. You should go back to the sections about configu-
ration and verify your settings.

Always approve your settings on Mach screen by pressing ENTER. Otherwise, the value will not be
saved.

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11.3 HOMING and software limit switches test

11.3.1 First homing

When axes are scaled correctly and motion directions are correct – it is time for first homing. During
normal work, most comfortable is to use a button for all axes homing („Ref All Home” on the main
screen). During the tests, it is better to home the axes individually from the Mach Diagnostic screen.

On the Diagnostic screen of Mach3 you will see group of buttons for each axis hom-
ing. Before you press one, be prepared for emergency stop by EStop pressing or
on Mach screen.
Every time you press Ref... verify homing of each axis used. After correct homing –
the light indicator next to the button should light green. If motion when homing is
wrong, you can change the configuration in „ConfigHoming/Limits”.

If axes homing is correct, you can experiment with increasing homing speed in
„ConfigHoming/Limits”.

11.3.2 SoftLimit switches

If axes homing is correct then you can set, switch and check software limit switches. Click on „Jog
Mode” in the manual feed rate panel and set „Cont.”. „Slow Jog Rate” set on e.g. 40%. It is worth to
turn on preview of machine directions by pressing on the Mach’s main screen. Then, in manual
mode go e.g. with X-axis- on 5mm before hardware switch limit and write down on paper - the X coor-
dinate from the screen. Repeat this action for all axes.
Open „ConfigHoming/Limits” window and enter correct values into SoftMax and SoftMin. For X and
Y axes it is usually SoftMin=0. You should remember that Z-axis usually works in negative direction, so
the SoftMax will be equal to zero, and min. limitation enter in SoftMin.

Close „Homing/Limits”, press and run homing again. Click on , to see the green light
around. You can try and go each axis to reach coordinates that are specified in the SoftMax/SoftMin.
The machine should smoothly brake and should not cross any limits of a working area.
After test is successfully finished you can turn the coordinates off by pressing .

After some parameters change – the controller may automatically go into emergency stop mode, it is
absolutely normal. In that case, you should press and run all axes homing by pressing „Ref All
Home” on the Mach’s main screen.

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11.4 Test of spindle and cooling.

At this stage, almost all major elements of the system were set and a machine is almost ready to work.
One important issue left – spindle test. Treatment with non-rotating spindle is generally not a good
idea.
Mach should be in active mode. The quickest way to test the spin-
dle is MDI mode. In the top bar press MDI. This mode lets you to
enter G-Code commands manually:
• Enter S command, with requested spindle revs e.g.
„S2000” – that is 2000 rpm speed. Approve with <en-
ter>.
• Enter M3 command (right revs) and approve with <en-
ter>. The spindle should start rotate right with re-
quested speed.
• Enter M5 command (stopping) and approve with <enter>. The spindle should stop.
• Enter M4 command (left revs) and approve with <enter>. The spindle should start rotate
left with requested speed.
• Stop with M5 command.
• Turn on cooling with M7, turn off - M30.
• Turn on cooling M8, turn off - M30.

It is good to check various revs values and revs change from maximal revs to very low. If you do not
use a braking resistor at inverter it may turn out that, when braking at high revs speed – the inverter
will report an error. Then you have to get yourself a resistor or lengthen the braking time.

In case of any problems, check again configuration settings and eventually the inverter settings. Usual-
ly the inverters have various control modes. Without proper configuration, the inverter will not re-
spond to outside signals.

Before spindle activation make sure if there is no loose collet. When braking at high revs speed the
tightening nut may unscrew and rotating collet may cause injury risk.

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12.Sample treatment step by step

To look closer at rules of using a machine equipped with CSMIO/IP-S con-
trol system – here is an example of a simple work.
An example includes area planning and logo milling in 30.6x30.6x48mm
size cube made of hard aluminum alloy.
Project design and G-Code file generating will be done with popular soft-
ware - ArtCam®. Logo file has AI format, which is very good for data
transmission between different software.
Aims:
• Planned area will be on 0,2mm depth cylindrical cutter with an 8mm
diameter.
• To set a base we will use a roller made of carbide with 6mm diameter, filed on half of diameter.
• The logo will be milled by engraving cutter 20 degree/0.6mm – on 0,3mm depth.

12.1 Project and G-Code files preparing

We create a new project in ArtCam software. Enter dimension
of the cube. In this example, the resolution is not very im-
portant so you can set it low.

Select Import Vector Data command in Art Cam and in the window that
pops up – option that will set our logo in the middle of defined area.

Next, we draw an object, which we use to plan the area. It would be good if the object were larger
than our cube, so that the cylindrical cutter will go
during the work with its whole diameter out of the
material. First, select an icon from the Vector tab, draw a rectangle with the same size
like our cube. In the Width and Height boxes enter 48 and 30.6 size. Next click „Cre-
ate” and „Close”.
Now you need to set the object position. Press right
mouse button on it and select „Transform Vectors”.
Select the lower left corner of the object and enter 0,0
position. Press „Apply” and „Close”.

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The newly created object with its position and size exactly coincides with the work-
ing area. Now you should add the additional enlargement that was mentioned, so
that the milling cutter will go with its whole diameter out of the material – thus we
get a better surface.
We click on our object and select „Vectors/Offset” menu position. The milling cutter
diameter is 8mm - we should give it a small reserve by entering as an Offset Dis-
tance the 8.5mm value. We are giving the Offset Direction as Outwards – that is the
outside. Offset corners – irrelevant here. Select - Delete original vectors, because
we do not need to save the original object.

At this stage, our project looks like this:

You can now generate trajectories for tools.

First, a tool path for planning the surface.

Select the object we have created and select Area Clearance icon from
Toolpath tab.
In Finish Depth box, enter treatment depth - 0.2mm in this case. In toleration area,
enter 0,01mm. As practice shows, it is not worth to overdo with toleration value. Of
course, if you have a high-class mechanics, granite construction, all is thermally
stabilized, and you execute precise jobs – you can set the toleration more detailed.
Safe Z parameter you can set at 5mm, Home Position at [0, 0, 10]. You can also
select „Add Ramping Moves” on default parameters, the result is smoother entry
into the material.

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You should inform the software what kind of tool you use. Below the Tool List click the Add button. In
the tool-base window, click Add Tool, to
add a new tool. Enter parameters as
the picture shows. Some parameters
like description or diameter are obvi-
ous. Step-down is a maximum depth
the tool gets. Stepover is a working
density. The bigger the density, the
generally better surface, but here it is
also not worth to overdo because you
can only unnecessarily make the treat-
ment last longer. Feed Rate is a feed on XY surface, and Plunge Rate means speed with which the tool
will get into the material. Tool Type is a tool shape type. Here the drawing, displayed after shape type
selection, is helpful.
In the end press „OK”, choose our tool from list and click Select.
In Tool List box, in the Area Clearance configuration panel there should our tool appear, now only
press Calculate: Now in the bottom of the panel, in the preview of working area there should the cal-
culated tool trajectory appear. We can switch to a 3D view to look closer. It should look something like
this:

Now we record the trajectory, go to the Toolpaths tab and click the icon.
In the record window, select so-called postprocessor, to define
output data format suitable for our control system. In ArtCam we
recommend „G-Code Arcs (mm) (*.tap)”. It is basic G-Code for-
mat suitable for Mach3 software. When you select the format
pres „Save” and save our trajectory as e.g. „planning.tap”.

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Next, generate tool trajectory for our logo.

Go back to 2D preview, and in the Toolpaths tab panel, next to the last gen-
erated path – deselect Show In 2D|3D. Previous trajectory disappears so it
will not disrupt our view.
Now select our logo and again click the Area Clearance icon. We enter
the parameters almost the same like before, only the depth is 0.3mm and
we deselect „Add Ramping Moves” – it will not be needed in this case, we
also need to define other tool. We proceed like before. Press Add - below
the tool list - and Add Tool in the tool base window. The parameters in this
case look like this:

You should note that, in ArtCam software a handle size is given as diameter,
and a dimension of tip of the tool (F) is as radius. Speed values in here are
quite low but it is only example, and not “high performance ride”, which
makes sense only for mass production for larger number of units. With so simple, single treatments it
takes more time to prepare the project, place the material and set the machine than the treatment
itself.
When our tool is entered, you can click Calculate: Now and record the path by clicking on the icon.
Postprocessor should stay the same. Name it e.g. „graw_logo.tap”. 3D preview should look like this:

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12.2 Preparing machine and Mach3 software

When files are ready, you only need to place and home the ma-
terial. First, start Mach3 software and reference all the axes
pressing „Ref All Home” button on the main screen.
Place the material securely, to avoid a risk of its shifting or
breaking during the treatment.
As it was mentioned at the beginning –
to set the material base we are going to
use the carbide roller, filed precisely on
half of diameter. If we use tool length
measurement, then enter the tool num-
ber “1” in a „Tool” box in Mach3 software and start the measurement by
pressing „Auto Tool Zero” button.

In the manual feed rate panel set continuous ride mode and 25% speed. At the same time in a Feed
rate box, you can enter stepper work feeds, which we will use in a moment -1000 mm/min.

Now use arrow keys or keys on a machine desktop, reach left edge of the material. Z-axis is a little
below the material level.
Next, change the feed mode for stepper mode and set the step on 0.1mm. Working
with 0.1mm step we get close to the material and then switch to 0.025mm step –
enter that value in a text box and press <enter>. Make the half of
the filed roller to contact with side surface of the material. If we
will try to move the spindle with a finger to any side – we will be
able to do that only to a small extent. The roller edges will not let
us more. Go by step with another 0.025mm until you will not be
able to move the spindle at all – it means that the material surfac-
es and the filed roller adhere to each other.

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At this point, we can set the material base in X-axis by clicking „Zero X” but-
ton on the Mach screen. Coordinate X on the screen will be reset.
Switch the feed rate mode on continuous one, „Slow Jog Rate” speed – e.g.
2% because we are very close to the material and the same way we set the Y
base on the lower edge of the cube. This way of homing seems to be a little
troublesome but with a little practice this can be done very quickly, besides it is quite precise.
When the position is set on the lower edge of the material then click „Zero Y”, to reset the Y coordi-
nate at this point.

If we do not use the automatic tool length measurement, setting a Z

base at this point makes no sense. You should set it only if we place
the right tool. However, I as-
sume that such a sensor is
installed in the machine.
For Z-axis, we set the base
much like XY, raising the axis a
little higher above the material
level, next lowering it in step-
per mode until the lower roller
surface touches the material.
Now click the „Zero Z” to reset the Z coordinate at this point.

The material base is already set so you can place the correct milling cutter – to plan the surface meas-
ure it and load the trajectory file.
After we placed the tool, we measure it clicking „Auto Tool Zero” button.

Automatic tool length measurement is not a standard Mach3 function. Description of this function
activation and configuration you can find in chapter 14.1 – „Automatic tool length measurement”.

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12.3 We begin the treatment

In Mach software, we select „File/Load G-Code” menu position or we click „Load G-Code” button on
the main screen. Select the file we created earlier: „planing.tap”. When the file is loaded, we can ini-
tially set the machine over the material and enter on the MDI screen.
• G0G53 Z0 <enter>
• G0 X0 Y0 <enter>
The firs command causes the Z-axis rises maximum high, the second one is to set the machines tool XY
axes in the defined earlier zero point of the material.
Go to the main screen again and click „Cycle Start” button – the treatment start.

Below a photo taken during the work:

You can change the tool for an engraving cutter and load the second,
previously generated trajectory. Before processing, there is one im-
portant detail. When planning the surface we lowered its level, the
engraving logo would be 0.1mm depth, and not 0.3mm like the one we
had assumed. “This can be easily remedied by reducing the zero point
level about 0.2mm (planned depth). Click on the text box that displays
current Z position and type on your keyboard "0.2 <enter>".

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After this operation, we can start work from the second file not forgetting about the measurement
after tool change („Auto Tool Zero” button).
When the file is loaded, and the tool is measured we can set the axes again over the material with the
MDI like before.

Press „Cycle Start” and start the treatment.

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13.A few practical notes about Mach3 software and CSMIO/IP-S

Here you can find few tips that can help users unfamiliar with Mach3 software.

1. Computer keyboard.
a. Do not use a wireless keyboard, sometimes this keyboard record keystroke, but
does not notice releasing it, which can be very dangerous while controlling the
machine.
b. In addition – an USB keyboard can behave in unpredictable ways. The USB port is
not resistant to interference therefore, especially on machines with servo drives
and higher power spindles. We definitely not recommend the USB keyboard.
c. The most reliable solution is PS2 keyboard or connection of industrial buttons to
CSMIO/IP-S digital inputs and defining them correctly in Mach3 software.
2. Remember that writing down the value in any text boxes on the Mach screen - must al-
ways be confirmed by pressing ENTER.
3. If you are doing CNC program at high speeds and sometimes the movement loses its
smoothness, check the „LookAhead” parameter in "Config / General config". It is respon-
sible for sections of the trajectory analyzed in advance. Set this parameter to 999.
4. If you are doing CNC program at high speeds and you notice some distortions related to
rounded corners then switch on and experiment with "CV Dist. Tolerance" parameter in
„ConfigGeneral Config”. At the beginning, you can set the value on 0,5 - it will corre-
spond to 0,5mm corner tolerance.
5. Mach3 software as a decimal separator (to separate the fractional part) uses a dot „ . ”.
Keep it in mind entering the values.
6. 3D trajectory preview on Mach screen can significantly burden the computer when the
files are large. While the machine runs, do not do operations such as zooming, rotation,
etc. For very large files, we recommend to turn of the 3D preview - Diagnostics screen,
click "Toolpath on / off."
7. If a machine has touched a hardware LIMIT switch, you can back of the switch by
"OveRride Limits" button activation on Settings screen. It is also convenience to activate
"Auto LimitOverRide" - this will cause that when we touch the limit switch a machine will
stop, but you can click RESET and back of the limit switches without any additional opera-
tions. Additionally the "Smart Limits" function activated will protect you against motion in
wrong direction, which can be cause by e.g. accidentally wrong button pressed.
8. Manual control (JOG).
a. Do not forget that pressing TAB key causes that additional side panel appears
where you can set speed, continuous or step mode – it makes that controlling
the axes and precise setting of material base is easier.
b. By pressing the combination of feed rate key (e.g. right arrow) and SHIFT key, the
movement is in continuous mode with 100% speed - regardless of the current
settings.
c. By pressing the combination of the feed rate key and CTRL key – the movement
is always in step mode with speed set in FEEDRATE area.

9. Mach3 always starts with tool „0” chosen, if you use a tools changer and some tool left in
a handle when you turn off, then after Mach restart, you must enter this tool number
(Tool Information group on the main screen, the "Tool").

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a. If you do not use a tool changer but you have an automatic tool-length meas-
urement sensor, then after starting Mach software always enter „1” <enter> into
the “Tool”. Similarly, when generating the g-code file in CAM software also al-
ways set the tool 1.

10. STOP button on Mach3 screen stops a machine instantly. With stepper motors, it may
cause that motor will fall out from the position, with servo drives, the motor controllers
may report an overload error or overstaying error and you will need to re-home the ma-
chine. Recommended way to stop the work is pressing pause first („Feed Hold”), and af-
ter it stopped – the STOP key.

11. To restart CNC program from specified location - set in G-code window desired position
(line), then press "Run From Here" and then "Cycle Start".

12. It is worth to know the basic commands of G-Code. In many situations the MDI Mach
screen, where you can manually type the commands that are executed immediately is a
very useful tool.

13. If you have a tool magazine and/or automatic tool-length measurement sensor, remem-
ber that any manipulation/repositioning or disassembly of HOME switches can cause ma-
chines absolute zero position shift and then recalibration of magazine and tool length
measurement sensor position is necessary.

14. If you set the zero point (material base) and you use an automatic tool measurement –
always make the tool measurement first, and then set the zero point. Setting the zero
point with unmeasured tool causes that the level of processing shifts when we place an-
other tool and call the measurement.

15. A PC computer you use to control the machine should be treated like an integral part of
the control system and should not be used to any other tasks. It means that, this com-
puter should only have operation system, Mach3 software and nothing else (eventually
text editor and file manager such as Total Commander®). For any other tasks such as de-
signing, you should use some other computer.

16. On the computer you use to control you should disable all visual effects of your desktop,
screen saver, and turn power profile on “always on”.

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14.VisualBasic® macros

On our website: www.cs-lab.eu you can download standard scripts for automatic tool-length meas-
urement and for automatic tool change. These are usually the most desirable functions and make
work easier. We encourage advanced users to learn more about macros, which provide great oppor-
tunities for self-expanding functionality of Mach3 software.

14.1 Automatic tool-length measurement

Automatic tool-length measurement is one of the most implemented function, e.g. because mechani-
cally it is very easy to do. If high measurement accuracy is required, the sensor
must be good quality. In CSMIO/IP-S controller – specialy for G31 command
(used during the measurement) – we implemented completely autonomous
movement operation and ultra-fast logic to assure measurement precision at
the highest level.

The measurement is made through the following stages:

• Raising Z axis at the maximum high (absolute zero)
• Going in a fast mode (G0) at XY sensor position.
• Quick exit (G0) by Z-axis to so-called - safe Z
• Going down in the measurement mode (G31) at "1" speed until signal receiving from the
sensor.
• Raising Z-axis with small value (preparing to measurement that is more accurate).
• Going down in the measurement mode (G31) at "2"speed, until signal receiving from the
sensor.
• After measurement is finished– raising Z-axis maximally.

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14.1.1 Configuration
Before we start the script configuration, you should follow these steps:
1. Check the sensor and inputs signals settings – go to Diagnostics tab and while pushing the
sensor with hand observe the light indicators on the screen. The light should light up
at the moment of pushing the sensor and light should go out after releasing it. In case of any
problems go to 10.4 chapter (input signals). The sensor signal in the configuration window is
called “Probe”.
2. Make reference move of all axes.
3. On the main screen switch the coordinates display mode for machine display (absolute) –

icon .
4. Secure the tool in the spindle holder (for the firsts test – the cheapest is the best).
5. In manual feed mode move to the center of the sensor measuring surface. Note XY coordi-
nates.
6. In stepper mode slowly lower the Z axis until the signal from the sensor appears and note the
Z coordinate.
7. Go with Z-axis up to the level you consider as safe. A small explanation here - as written
above, while measurement there is rapid slide down to some level by G0 command first. You
have to assess to what Z-axis level it can slide down quickly. It depends on maximum length
of tools that will be measured. You can also enter "0" as a safe Z and then measurement
starts from the top position.
8. Move the XY axes to place yourself somewhere above the worktable.
9. Using the stepper mode, slowly slide the tool down to the worktable surface and note the Z
coordinate.
10. Turn off the absolute coordinates mode by clicking icon.

When you have noted all necessary data, open the downloaded toollenght.m1s file in any text editor
(e.g. notepad). Then select all using mouse or by pressing "CTRL + A" and copy to clipboard - "CTRL +
C".
In Mach standard graphical interface, on the main screen
there is an "Auto Tool Zero" button. This button is defined
by default as calling a macro, so there is no need to add a
new button in the graphical editor.
To connect the mentioned above button to our macro, se-
lect in the menu: "The operator / Edit Button Script". The
"Auto Tool Zero" button and several others should start to
blink. Click on it and open Mach3 text editor.
Sometimes there is a single text line, if so - you must delete
it, and then press CTRL + V to paste our macro.
Now just enter a few parameters based on the coordinates,
which we noted earlier. All configuration data can be found
under "Configuration parameters" line.

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Parameter Details
SENS_Z [Z coordinate of sensor activation ] – [Z coordinate of table level].
If you e.g. when reaching the table Z=-122.070mm, and sensor gave an active signal at
Z=-110.656mm – the entered value should be 11.414.
Z_SAFE It is parameter that describes at what height the Z-axis can slide down fast (G0). If we have
doubts how long tools will be measured it is safer to enter „0”.
SENS_X/SENS_Y X and Y position of the sensor in a machine tool working area.
MAX_DTRAVEL Maximum distance the axis travels down in the measurement mode. If in measurement
mode the Z-axis run this distance, and the sensor signal does not appear – the measure-
ment failed. With this parameter, you can protect yourself from a situation when the
measurement was called while the tool was not clamped.
SPD_FAST First measurement speed (mm/min).
SPD_FINE Second precise measurement speed (mm/min).
Z_LIFT Determines how much the Z-axis should be raised before the second measurement. The
value should be large enough to change the sensor inactive again while rising.
Z_PARK Z-level, on which the axis was set before the measurement and after the measurement is
finished. Usually – “0”.

Macro should be saved in „FileSave” menu, close the window. After the operation you should also
close and restart Mach3 software to make sure that the settings were saved.

That is all. Just click the „Auto Tool Zero” button, and the tool will be automatically measured. Why
the table level was checked? It is because adding data the way we showed above – after correct
measurement - zero of Z-axis is set on the worktable level. Now if we want to define the zero point of
the work piece, and its thickness is e.g. 10.150mm we can enter this value directly into the „Offsets”.
In short, the treatment offset in Z-axis is counted from worktable level. Moreover, if we switch „Auto Z
Inh” and „Z Inhibit” functions in plugin’s configuration then on Mach3 screen – the controller will acti-
vate protection so the tool will not go below working table area. For both JOG movements and g-code
making. This way we protect ourselves against worktable damage.

14.2 Automatic tool change macro

On our website http://www.cs-lab.eu you can find sample macro that supports automatic tool change
(m6Start.m1s). Unfortunately, because of the fact it is more complicated and that very often spindles
from different manufacturers have different information signals logistic – it is often required to adjust
such a macro strictly to a concrete machine tool.
CS-Lab S.C. Company provides also services for launching, configuration and adaptation of control
system to specific requirements.
We also offer complete solutions - the entire control box, launching, configuration and preparation of
the macro for specialized tasks, etc.
If you are interested in our offer - please contact with our office: office@cs-lab.eu , +48 52 374 74 34.

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Addition A – Slave axis configuration example

With bigger machines you often need to use so called – slave axis. It is about that the physical axis of
the machine is powered by two motors.
We implemented in CSMIO/IP-S device the slave axes function with additional option to adjust
geometry of a machine. Geometry regulation is very useful if you want to set perpendicular axes pre-
cisely.
To understand the rule of slave axis configuration we will use a very common example
• XYZ 3 axis plotter
• Transmission of a drive - toothed bars
• X-axis (gantry) controlled by two motors both sides with pulleys.
• Used phrases: master axis (main) and slave axis (slave).

Defining axes used in Mach3 software

In „ConfigPorts and Pins” menu, enable the X, Y and Z-axes.
Slave axes are A, B or C. We do not enable the slave axes
here. CSMIO/IP-S controller supports slave axis autonomously
and activating it as a normal axis may cause conflicts.

Axis scaling and configuration

We assume that the machine is properly configured as it was described in chapter 10. In
„ConfigMotor tuning” menu we only configure the Y-axis (master), slave axis is configured
automatically. It is important that master and slave axes have the same steps number per millimeter,
so you cannot use motors with different encoders or different pulleys.

Activation and choice of slave axis

Slave axis function is set in plugin configuration window
–„ConfigConfig PlugIns” menu by clicking on „config”
next to CSMIO-IP position.
In the example the axis that has two drives is X axis and
its assigned slave axis is B axis (A-axis is free, if we would
need a rotary axis in the future).
In „ Slave Axis Configuration” group we choose B as
„Slave”, set the mode for now to „No correction” and
„Geometry Correction” to 0.

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LIMIT and HOMING switches

On both – slave and master axes side – there should be separate LIMIT and HOME switches. The sig-
nals should be properly set in Mach3 software („ConfigPorts and Pins”).

Before next steps it is necessary to verify if the signals are correctly configured (DIAGNOSTICS tab) Pay
special attention whether HOMING switches are not replaced. Pressing by hand the HOME switch on
„X” motor side the M1HOME should light up, presing HOME switch on „B” motor side - the M5HOME
should light up.

Axis direction settings

One of the most important issues is correct setting of movement directions for master and slave axes.
In our example, drive is transmitted by toothed bars. In this case, usually there is need to change slave
axis direction. We can do it in „ConfigHoming/Limits” by setting „Reversed” at „B” axis. The direc-
tion can be also changed in servo drive.

Manual feed test

When all the steps described above are already done, you can attempt to test the axis working in the
manual feed. A small note: At the beginning, the best is to set very low speed - even 0.5%. You should
first verify whether the motors are working on both sides and whether the feed goes in good
directions.

Automatic reading of HOME switches position difference

Before we activate the mode slave axis with geometry correction, you should know what is the posi-
tion difference of HOME switches on master (“X”) and slave (“B”) side. Homing with geometry correc-
tion is about that master axis always finishes homing at the moment it goes back off its HOME switch,
and slave axis goes to: [HOME switch back off position - correction]. If we gave zero correction initially
and HOME switches position on both sides differs by e.g. 10 mm - then there would be issues with
gantry during homing.
To avoid this situation there is additional mode created - for HOME switches position difference
measurement.
In plugin configuration window for “X” axis in “Slave Axis Configuration” group enable the „Read Dif-
ference” mode and start homing. After homing is finished, open the plugin configuration window
again and in „Geometry correction” area there should be the value from the measurement.

Geometry correction mode activation

After correct measurement of HOME switches position difference, in the configuration window you
can activate „Sl. correction” mode for „X” axis. Since now on, we can adjust the perpendicularity by
modifying "Geometry correction" value. For perpendicularity measurement, we recommend
Renishaw® Ballbar system.

You should not use stepper motors for slave axis. Lack of position feedback causes a risk of mechanics
of machine damage. With servo-drives, you should always have alarm signals configured correctly.

CS-Lab Company made every effort to ensure reliability of CSMIO/IP-S controller. However, our
company does not take any responsibility for any mechanics damage because of wrong configuration
and any eventual failure or software errors of CSMIO/IP-S controller.

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Addition B – CSMIO/IP-S firmware update

We invite you to visit our website: http://www.cs-lab.eu for CSMIO/IP-S firmware updates in a „down-
load” section. The controller updates includes corrections and often enrich the device with new fea-
tures so it is worth to update the controller regularly.

How to check current firmware version

You can check the controller current firmware version in
the diagnostics window from „PlugIn Con-
trolCSMIO_IP_plugin” menu.
The current version is shown on the bottom bar.

Update application (uploader)

After installer file download – „setup_CSMIO-IP-S-x.xxx.zip” double click and start setup_CSMIO-IP-S-
x.xxx file (x.xxx is a firmware version). Installation process was described in chapter „9.3 – Installation
of CSMIO/IP firmware”.
At the end of installation leave „Launch CSMIO/IP-S Controller Firmware” option selected and click
„Finish”. The application will be launched automatically, thanks to it we update CSMIO/IP firmware.
Below you can see the application window and sequence of actions that should be done.

If you run the update application from installer file it means that correct file with the firmware was
already loaded and „Open App. File” button is not active. If there is only one CSMIO/IP controller in
network - the application asks to start the update automatically. If there are more controllers then you
should chose one IP address from a list to update the controller you want and click „Flash Programm”.

CSMIO/IP-S controller is protected if update fails. There is always a possibility to try again

Before update – close Mach3 software.

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If you install new firmware version but you do not update with uploader application then Mach3
software during start will inform you about incompatibility between versions and communication will
be interrupted.

Plugin file update

Plugin is updated automatically during CSMIO/IP firmware installation.

Update verification
After firmware update is finished, you can start Mach3 again and open diagnostics window. In the
bottom bar, you should see your update firmware version.

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