An unhandled exception generally means that, in the program code, the program is not checking against every possible exception that could occur. Most likely, this exception is caused by some limit that is being exceeded (or the other way around). I would remove any files that could be associated with the program, like setting files, or even register configurations associated with that software. Also, make sure that you completely update your version of windows.

Check to make sure all of the drivers are current for your graphics hardware. Make sure that your graphics hardware works in other programs as well.

If you upgraded the Windows version, check to make sure your graphics hardware is compatible with the new version of Windows. Unhandled exception issue may be associated with graphics hardware and compatibility.

Customer Response:
I've given up on the wiped laptop and loaded the program on a different computer using windows 8. At first it won't operate my CNC until I read on Planet-CNC forum about loading the drivers on windows 8. All working now. Will run through the calibrations again today. Thanks

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I had to wipe my computer due to virus and now can not download the USB software again. I get a "unhandled exception" error message. Any suggestions?

I have not come across this problem, but there may be USB, or firmware issues that you are experiencing. I would recommend going on the polabs website and using their support center (https://support.poscope.com/)and posing that question to them. Also, have you tried the ethernet port as an alternative to see if that helps?

Here is the response from an LLM:

Check USB Cable and Port: Start with the basics. Sometimes this error is due to a poor USB connection. Ensure you're using a high-quality, shielded USB cable and that it's plugged into a USB port directly on your computer, not through a hub. If possible, try a different USB port or a different cable to rule out any issues there.

Update Firmware and Software: Ensure that both your PoKeys57CNC firmware and the Mach4 software are up to date. Firmware updates for your PoKeys board might include optimizations or fixes that address connectivity issues.

USB Polling Rate: This error can also arise from the USB polling rate setting in the PoKeys configuration software. It might be set too high for your system's ability to handle it. Try lowering the polling rate and see if that resolves the error.

Computer Performance: Check your computer’s performance. If it’s running several heavy applications simultaneously, it might not be able to process signals from the PoKeys board fast enough. Try closing unnecessary applications or consider using a dedicated machine if your current setup is too taxed.

Mach 4 and PoKeys Plugin Configuration: Dive into the Mach 4 plugin configuration for PoKeys. Ensure that all settings are correctly configured as per the manual. Incorrect settings might lead to communication bottlenecks.

Connection Quality and Interference: Consider any potential interference sources near your CNC setup or computer. Electromagnetic interference from large motors, other electronics, or long cable runs can affect communication quality. Try rearranging your setup to minimize interference.

Consult Documentation and Support: If the issue persists, consult the detailed documentation provided by PoKeys or reach out to their customer support. They can offer more specific advice based on the latest product updates or known issues.

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I HAVE FOLLOWED YOUR YOUTUBE VIDEO ON SETTING UP THE POKEYS 57CNC BOARD BUT WHEN OPEN MACH 4 GET A ERROR MESSAGE CONNECTION IS TO SLOW

I have not come across this problem, but there may be USB, or firmware issues that you are experiencing. I would recommend going on the polabs website and using their support center (https://support.poscope.com/)and posing that question to them. Also, have you tried the ethernet port as an alternative to see if that helps?

Here is the response from an LLM:

Check USB Cable and Port: Start with the basics. Sometimes this error is due to a poor USB connection. Ensure you're using a high-quality, shielded USB cable and that it's plugged into a USB port directly on your computer, not through a hub. If possible, try a different USB port or a different cable to rule out any issues there.

Update Firmware and Software: Ensure that both your PoKeys57CNC firmware and the Mach4 software are up to date. Firmware updates for your PoKeys board might include optimizations or fixes that address connectivity issues.

USB Polling Rate: This error can also arise from the USB polling rate setting in the PoKeys configuration software. It might be set too high for your system's ability to handle it. Try lowering the polling rate and see if that resolves the error.

Computer Performance: Check your computer’s performance. If it’s running several heavy applications simultaneously, it might not be able to process signals from the PoKeys board fast enough. Try closing unnecessary applications or consider using a dedicated machine if your current setup is too taxed.

Mach 4 and PoKeys Plugin Configuration: Dive into the Mach 4 plugin configuration for PoKeys. Ensure that all settings are correctly configured as per the manual. Incorrect settings might lead to communication bottlenecks.

Connection Quality and Interference: Consider any potential interference sources near your CNC setup or computer. Electromagnetic interference from large motors, other electronics, or long cable runs can affect communication quality. Try rearranging your setup to minimize interference.

Consult Documentation and Support: If the issue persists, consult the detailed documentation provided by PoKeys or reach out to their customer support. They can offer more specific advice based on the latest product updates or known issues.

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[596] I have followed your YouTube video on setting up the pokeys 57cnc board but when I open Mach 4 I get a error message the the connection is to slow

Yes, the RNRMotion.dll file must be used and put in the plugins folder under the Mach3 folder.

The XML file that I link on the Mach3 USB controller page is the file you should start with. This file will have the necessary configuration that links the Mach3 USB controller to the Mach3 control software. You can then make whatever changes you need to this configuration to tailor it to your machine.

Do you see a quick flashing red led on the board when you press the arrow keys?

Additional Information:

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[575] Do I have to use the motion driver and configuration file to use this card? The x,y,a shows that it's moving on display, but the motors aren't moving.

You can find the wiring diagram for the Mach3 USB card on its product page here:
https://www.buildyourcnc.com/item/electronicsAndMotors-electronic-component-breakout-Mach3-USB-Board

Here is a direct link to the diagram:
https://www.buildyourcnc.com/Documents/Electric%20Wiring%20Diagram.pdf

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I need wiring diagram for motor to driver to usb motion card. I cannot find diagram. I have been unable to get information for a week.

What interface board are you using? Typically, this will be an issue with the computer that MAch3 is installed. The only other component that may affect this would be the interface between the computer and the machine.

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mach3 freezes in the middle of a run, I don't get any message. I have press reset and then the jog buttons work. I have to reset the zero and start from the last line when the machine stopped. It happens mostly during the finishing part of the g-code file

The relay is only used for devices like routers, spindles, coolant, mist, etc. The relay works like an automatic switch and will allow current to pass when the relay is engaged.

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The relay doesn't have a A+ B - it has signal in god. 5v. / 0 S P. This has to go to my USB motion card wiring shows v+ goes to top of coil no number and comes out the bottom to #2 the relay I got from you is not that simple

Are you able to install a newer version of Mach3? If you are worried that your configuration will be lost, you can save the configuration by copying all of the XML files from the Mach folder. The XML files contain all of the settings that you applied in Mach3. Just in case the XML files are not compatible with the new version, make sure not to erase the current Mach3 that you have on the machine.

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[575] Hi, I have an old version of MACH3 V1.84 - Can someone tell me where to place the USB motion drive as there is no plugin folder in this version.

Yes, the Mach3 USB controller will work with the latest Windows version and in 64-bit mode. The 32-bit mode is only relevant for using the parallel port driver if you are using a parallel port breakout board. Since this controller is connected via a USB cable, the 64-bit state will work fine.

Additional Information:
mach3 not showing in device manager

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[575] I have a 64 bit Windows 11 laptop. Will this interface board work with this? If not is there an option you can suggest.

If your PC is unable to communicate successfully with the Mach3 USB controller that you purchased, the problem can exist outside of the controller. If the problem is with the controller, then my controller will work. If the problem is not with the controller, then the problem will persist.

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[575] I have one of these but pc says device is faulty. If i buy one from you will you be able to fix such problems

I haven't delved into using encoders with stepping motors too much. From my research, you need to have a controller that can provide the closed loop control, rather than software handling that process. I have also found from my research that using encoders on stepping motors is generally used to stop the machine in the case that the motor failed to achieve the commanded position for some reason and gives the user the chance to correct and continue with the job.

If you want proper closed loop control, it may be best to go with servos and servo controller that provide the closed loop control within the real of those two components.

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I HAVE NOT SEEN ANY REFERENCES TO ENCODER FEED-BACK CAPABILITY IN OF THE HARDWARE YOU SELL. THIS A SUPPORTED FEATURE WITH HARDWARE/SOFTWARE SELL?

The Mach3 USB controller does not provide 5V output signals. The Inputs, Outputs, and PWM Spindle Speed terminals are separated from the 5V side of the board. The output terminals use the 24V portion of the controller and you will need a 24V power supply to make these outputs work.

Please watch the video below to completely understand how the outputs of this controller work. Make sure that you are using the RNRmotion.dll plugin and that the port for each of the outputs is set to port 3.

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[575] I cant get a 5v signal on any of the Outputs on the board. what Port# and Pin #s should I be using on Mach3?

Rnrmotion.dll is a dynamic link library that is very similar in function to an executable program, or app. Since a dll is executable, malicious code can be embedded in that type of file, so windows will automatically flag all files of this type. You just need to make sure you are downloading from a trusted source. The emotion.dll file on our site is clean, but still, run windows defender against it to make sure.

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why do I get the message "RnRMotion.dill was blocked because this type of file can harm your device"?

The mach3 USB controllers that we stock don't have green LEDs. Can you tell me what brand you are referring to?

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2017 Mach 3 usb motion card not translating commands to machine. Second green led by limit switch terminals. Seem new. MDI won't move spindle. Any Ideas?

To bring the machine to the origin, click the "Ref all Home" button. The machine will move to the limit switches. If the axes are not zeroed automatically, you can zero them by pressing the zero button for each axis in the digital readout (DRO) section.

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[575] after coplete work all axis are not coming in orign point but mech3 show all axis are origen point

What is the actual error that you are seeing in Mach3 and what CAM program are you using? Did you try installing a later version of Mach3 if your's is an earlier version? What post-processing setting are you using in your CAM program?

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I am getting that radus error in Mach3 and changing my IJ setting is not working. Any suggestions?

dL usually stand for a short that is occurring within the spindle or spindle wiring. I would recheck the wiring going from the VFD to the spindle, as well as the terminal on the spindle where there should've been some soldering required. We usually tend to either heat shrink or use electrical tape to cover the terminals so no contact or arching can be present.

Also depending on the VFD you have please adjust the setting pd008, to the voltage that is required (110V/220V).

If the issue proceeds please contact use at customerservice@buildyourcnc.com, for further assistance or replacement.

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How can we check our 1.5kw spindle. we get a dL error after we start to cut. it spins up fine. We checked IGBTs in the VFD and they're not shorted. We suspect intermittent short INSIDE the spindle. What do you think?

Text the image to 281-815-7701.

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I set up my limits in Mach3 but after restarting machine/program it does not allow me to use them, keep getting error they are out of limits. I have a picture of how they are set and worked at least one time. but not sure how to share it

Try the probe connected between the input and DCM with just wires connected to those terminals. When you short the two wires, you should see the change in the diagnostic screen.

Make sure that the probe configuration is correct:
Config -> ports and pins -> inputs tab
on the probe line, make sure the pin number matches the IN number on the controller. Make sure that the port number is 3. And finally, make sure the active low is set correctly. Toggle the active low to toggle the normally open and normally closed state of the probe.

Additional Information:
Nothing changes in the diagnostic screen, however the Digitize led is lit. One wire on in4 the other on DCM. If I were to put a multi-meter to any of the pins would there show any voltage?

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[575] I have my probe conected and have checked continuity but my probe does not show to be working. What else could be wrong?