Thank you for purchasing the Raspberry Pi Parallel Hat for LinuxCNC! This setup instruction assumes you are using the 5 axis breakout board that is available everywhere. There shouldn't be any difference between the green and blue breakout boards and either one should work.
Download the LinuxCNC RTOS Image
Please download the latest uSD card image from linuxcnc.org.
https://linuxcnc.org/downloads/
Make sure to download the correct version based on whether you are using a Pi4 or Pi5. For Pi3, use the Pi4 image:
Burn the uSD Card
If you use Linux to burn the image to the uSD card, the Raspberry Pi Imaging application seems to work well:
https://www.raspberrypi.com/software/
If you use Windows, the Raspberry Pi Imaging application can also work, but it crashes on some Windows machines, so an alternative is the Balena Etcher:
Physical Connections
Please click on the image for a larger version.
The 5 axis breakout board comes with a male to male USB cable. Throw it away and don't even let it get near the junk drawer of random cables. It should not exist. The 5 axis breakout board will get it's power from the "PC5V" and "GND" terminals on the bottom edge. Higher voltage for the 0-10V analog output is obtained from the "GND" and "+12-24V(IN)" terminals on the right side. The above image shows two separate power supplies, but a single 24V power supply could easily be used for both the breakout board and the stepper motor drivers.
In order to connect the 5 axis breakout board directly to the Parallel Pi Hat, please remove the small standoffs on the parallel pi hat DB25 connector using a pair of needle nose pliers.
If you are using a DB25M-F parallel port cable to connect the Parallel Hat to the Breakout board remotely, leave the standoffs in the Parallel Hat as they will be necessary to secure the cable to the board.
A simpler connection diagram is located here:
https://www.jbcnc.se/images/datasheets/DB25_0-10v.pdf
A general wiring best practices guide is provided by LinuxCNC here:
https://linuxcnc.org/docs/stable/html/integrator/wiring.html
Power
The Raspberry Pi 4/5 needs to get its power from a USB-C connector on the Raspberry Pi board. If you use a 5V power supply with screw terminals, either cut up a USB-C cable to access the internal wires, or a USB-C cable can be ordered from us that just has the power and ground wires inside.
The Parallel Pi Hat will receive its power from the Raspberry Pi through the 40 pin connector.
What isn't shown on the above diagram is the need to connect the breakout board to a 5V power source using one of the PC5V terminals. Be sure to connect one of the breakout board GND terminals to the 5V power supply ground. If you are using the analog output or relay on the breakout board, it will also need to be connected to a 12-24V power supply.
I recommend using a single 5V power supply to power both the Pi and the 5 axis breakout board logic. A 24V power supply can power the stepper motors and the analog side of the breakout board. Powering the spindle is setup dependent. Contact us if you have any questions.
For each of the power supplies in your system, please connect all DC ground (GND, -V, etc.) together. All power supply chassis, router chassis, etc., should all be connected to earth ground. AC Line and Neutral should only go to power supplies or the VFD, preferably through a fuse or breaker on the line side. Please follow all local electrical code requirements when working with more than 40V. Be safe!
Starting Up
After booting the Raspberry Pi, use "cnc" as both the username and password as mentioned in the above image. Then open a terminal and type "sudo menu-config" like is shown in the above image to run the config tool to set up the time zone and other location based information.
At this point it is helpful to connect the Raspberry Pi to the internet to be able to download the sample HAL files.
HAL File
In order for LinuxCNC to control the machine, it needs to know what pins to toggle to make the machine move. HAL stands for Hardware Abstraction Layer which in general is a software layer that allows multiple types of hardware to be used by the same high level software without any need to change it. The software layer in between the hardware drivers and the high level software (the core of LinuxCNC) is the HAL.
The HAL is configured using the ".HAL" file which is like a .INI file for those of you who remember early Windows software. The HAL file is cryptic and has a super steep learning curve, but for those of you who want to learn more about it, documentation is available at:
https://linuxcnc.org/docs/stable/html/hal/intro.html
For the rest of us, it is easiest to copy and paste known working setups into the HAL file.
Start LinuxCNC and go through the wizard for machine setup. It will generate a configuration that includes a HAL file. Write down the name to that HAL file, then rename it or zip it up to archive it since it won't be needed any more, but you do want to keep it handy just in case you need to revert back to it later.
Download the sample HAL file for the specific Pi you are using from the Byte 2 Bot website and rename the HAL file to what the original HAL file name was. Place it in the same folder as the original was. The sample HAL files are already set up to use the 5 axis breakout board.
Modify HAL
The sample HAL file contains all of the information to control the X Y and Z stepper motors using the 5 axis breakout board. It also defaults to use the DC motor spindle control on the parallel hat.
Spindle Options
DC Spindle
The sample HAL files are already set up to use the MOSFET on the Parallel Hat to control a small DC Spindle motor.
Laser
Small laser modules should also be able to be used with the Parallel Hat. Some lasers may not work well with PWM control, so please refer to the laser module documentation before setting up the HAL file. I have personally used LinuxCNC with a on/off control to a SolVol diode laser. The sample HAL files include example setup for dithering (PWM) output to a laser, and can be uncommented to be used.
VFD (Analog)
If you use a VFD (Variable Frequency Drive) to control a spindle, the easiest way to control it is to use the 0-10V analog output on the 5 axis breakout boards. The Pi will generate a PWM output that can be use as an analog input on the VFD.
Connect the "PWM 0-10V<OUT>" pin to the analog input on the VFD. Also, connect the "GND" pin to the VFD for the analog return as well. The terminal names are really only visible on the back of the 5 axis breakout board:
VFD (RS485)
If you use a VFD and want to use a RS485 connection, the following HAL lines could be uncommented by removing the '#' symbols. Don't forget to comment out the HAL commands for the DC spindle if this is the route you choose.
The Parallel Hat will use /dev/ttyAMA0 as the serial port. Please see the other blog post about configuring the Pi for serial communication. Other serial services may need to be disabled to use the serial port on the pi.
https://byte2bot.com/blogs/instructions/setting-up-a-raspberry-pi
Please note that the HAL VFD example lines were obtained from the internet and I have not actually tested these to confirm that they work. If you get your VFD working with the RS485 port, please let us know what HAL file commands you used so that we can update our sample HAL configuration files. There are many different VFD manufacturers on the market, and the setup could be different for each depending on the communication protocol, so even if the sample HAL configuration is supplied, it may not work with your exact VFD. That is why it may be easiest to utilize the analog input feature on your VFD.
Limit Switches
The sample HAL file is already set up to use X,Y, and Z limit switches for homing. It also assumes that three more limit switches wired in series to tell the software that one of the axis moved beyond the maximum travel limit. The software won't know what axis caused the switch to open, but it will just stop and let the operator figure it out.
When configuring the HAL file for your limit switches, the pin numbers you use in the HAL file are relative to the Pi 40 pin header. Here is a table that correlates those pins to the breakout board connectors:
|
Pi Header Pin (HAL File) |
Breakout Board Terminal |
Byte2Bot Sample HAL usage |
| pin-22 | P10 | unused |
| pin-24 | P11 | all-limit |
| pin-26 | P12 | min-home-x |
| pin-32 | P13 | min-home-y |
| pin-33 | P15 | min-home-z |
Changing the homing behavior is covered by the following guide:
https://linuxcnc.org/docs/stable/html/config/ini-homing.html
Troubleshooting
Before going too far into troubleshooting specific items, it is important to note that LinuxCNC has quite a few debugging features in it already. These features can be used to view signals (inputs or outputs). Knowing the state of those inputs or outputs could help diagnose the problem.
In my experience, 99% of the time, I am only debugging to figure out how to setup things correctly.
Parallel Hat
After powering on, the Parallel Hat 5v and 3.3v LEDs should illuminate. If they don't, then there is a mis-alignment of the 40 pin header, or some other hardware issue. Please fix it immediately or damage to the Pi might occur.
The Parallel Hat will not appear as a parallel port in Linux like a USB parallel port or serial port will. There will not be an entry in the /dev folder. LinuxCNC will use each pin as a GPIO, not as a single parallel port.
LinuxCNC Errors
TBD. Honestly, there could be a whole book written here. Contact us if you run into a problem and we will try to help. In most cases, LinuxCNC will crash and give you an error message window. The most effective way to get around this is to either google the error message or to go back to a working HAL file and start making changes incrementally to see what breaks it.
Stepper Motors
When initially setting up my machine, controlling 2 stepper motors worked, but once I tried to connect the third stepper motor driver, they stopped working. This was due to how I incorrectly connected the enable signal to all three of the stepper drivers. I tried to use the breakout board output to source the current needed for all three driver enable signals. The 5 axis breakout board can sink more current than it can source. The drivers I use have an opto-coupler inside which consist of a diode (LED) and a light sensitive transistor.
The correct way to connect the stepper drivers is to connect the Anode (triangle side) of the opto-coupler diode to the 5V terminal (PC5V) on the breakout board. The cathode (line side) of the diode should get wired to the step/direction/enable pin on the breakout board. This allows the breakout board to pull the output low and then current can flow through the opto-coupler inside the stepper driver.
Here is a link to LinuxCNC Stepper troubleshooting:
https://linuxcnc.org/docs/stable/html/config/stepper-diagnostics.html
DC Spindle Motor Won't Turn Off:
There are 3 reasons why the DC Spindle motor might run continuously.
1. The wires going into the Parallel Hat are connected backwards. The "P/S GND" terminal needs to go to the DC spindle power supply ground. The "LOAD -" terminal needs to go to the low side of the motor. If those connections are reversed, there is a diode on the Parallel Hat that would allow current to flow through the motor, bypassing the MOSFET that controls it. So please double check the connections.
2. The config file might not be set up correctly, please confirm that the spindle configuration options are the same as the sample HAL files. Chances are, if this is the problem, the motor will only run when LinuxCNC is running, or run up until when LinuxCNC starts.
3. The MOSFET or diode are damaged. This can occur if the motor is too large for the Parallel Hat. If you have a multimeter with a diode option, you can check this by measuring the D6 diode on the Parallel Hat. With the power turned off, your meter should read about 0.2V across the diode in one direction and open in the other direction. If the meter shows less than that, the diode may be damaged. Damage occurs when the kickback voltage/current generated by the motor is too high. Please contact us do discuss options for repair of your board, or other higher current options for the DC motor.