2000 Series PoKeys Operator Panel: Startup, PC Power Button, and Troubleshooting
Applies to: MachMotion 2000 Series controls with a PoKeys-based operator panel (including the X15-02-24 panel). This guide explains the normal startup and PC power/reset button behavior. Panel revisions and motherboard settings can differ; do not assume a particular signal polarity or wiring pin from this overview.
How the parts work together
| Part | Role |
|---|---|
| PC motherboard and BIOS | The industrial PC starts and provides a startup signal to the PoKeys device. Its BIOS and power-button settings affect startup and shutdown behavior. |
| PoKeys device, relay, and button board | The PoKeys hardware reads the operator-panel buttons and drives the relay. The relay routes the PC Start/Reset button according to whether Mach software is controlling the panel. |
| Operator-panel buttons, lights, and beeper | The physical user interface. The PC Start/Reset button has a hardware PC-power path and a software reset path. |
Signal-flow diagram
| Startup signal | PoKeys panel hardware | PC and software |
|---|---|---|
| Motherboard/BIOS HIGH or LOW transition → |
PoKeys input → PoBlocks startup sequence beeper, power indicator, light marquee |
Mach software later communicates with PoKeys → panel inputs, outputs, relay command |
| PC power-button header ← relay default path |
PC Start/Reset button → relay contacts and PoKeys button input |
Mach software reset ← button input when running |
The arrows show functions, not connector pinouts or a complete electrical schematic.
Which software does what?
| Software | Purpose in this panel |
|---|---|
| PoKeys configuration application | Connects to the PoKeys device for diagnostics and testing of the device and button inputs. Use configuration or recovery functions only with the correct panel files and guidance from MachMotion Support. |
| PoBlocks | The logic stored on and running in the PoKeys device. For this 2000 Series panel, its intended startup action is triggered by the motherboard signal transition. It handles the initial beeper, power light, and sequential light display (marquee). After that startup event, it should not keep commanding normal button-panel outputs. Incorrect PoBlocks logic or the wrong startup polarity can cause unexpected behavior. |
| Mach software | Runs on the PC, processes panel button inputs during normal operation, controls panel functions, and commands the relay that changes the PC Start/Reset button from the PC-power path to the software reset path. This description applies across Mach software versions. |
| Motherboard BIOS | Firmware rather than a panel application. Its power and startup settings, and the motherboard's HIGH/LOW startup signal, can affect this circuit. |
What happens at startup?
- The PoKeys device has power and runs its stored PoBlocks logic.
- When the motherboard powers on, its startup signal changes state. The active state may be HIGH or LOW depending on the motherboard and the matching PoBlocks program.
- PoBlocks responds to the configured transition with the initial beeper and panel-light sequence. The startup sequence is meant to run once per motherboard startup signal transition, not continuously during normal operation.
- Once Mach software is running and has control of PoKeys, it commands the relay and handles the normal button functions.
What does the PC Start/Reset button do?
| Relay state | Button action |
|---|---|
| De-energized (default; Mach software has not taken control) | The button is connected through the relay's default contact path to the PC start/power circuit. A press can start the PC. Holding it can request a forced PC shutdown, subject to the motherboard's power-button behavior. |
| Energized (commanded by Mach software) | The relay removes the button from the PC power-switch path. Pressing it is still reported to Mach software as a reset input, but holding it no longer forces the PC off through that button. |
If Mach software or the PC freezes: The relay can remain in its last commanded state. If it remains energized, the panel button cannot force the PC off even if held. If the control does not respond, follow the approved power isolation or recovery procedure for your machine. Do not rely on this button as an emergency stop; use the machine's designated E-stop for a hazardous condition.
Troubleshooting by symptom
- No startup beeper, power light, or marquee: Check whether the PC and panel receive power, then note whether the motherboard actually starts. A missing or differently polarized motherboard startup transition, incorrect PoBlocks configuration, or PoKeys power/connection issue can prevent the startup sequence. Record the control serial number and exact symptom for Support.
- Startup lights repeat, remain on, or behave unexpectedly: Check whether the motherboard is repeatedly restarting. If it is stable, have Support verify the matching PoBlocks file and expected HIGH/LOW trigger for this motherboard. A program intended for another motherboard revision may trigger at the wrong time.
- PC will not start from the panel button: Determine whether panel power is present and whether the button works mechanically. With Mach software not running, the relay should provide the default PC start path. Support can check relay state, button-board continuity, motherboard power-button input, and BIOS power settings.
- Button resets Mach software but will not shut off the PC: This is expected while Mach software has commanded the relay on. Use the software's normal Power/Shutdown control for a routine shutdown.
- Button will not force shutdown after a software freeze: The relay may be latched in the software-controlled position. Treat this as a PC/software recovery issue; use the approved power isolation procedure and contact Support if it recurs.
- Buttons or lights fail only after Mach software opens: Compare behavior before and after launch. Verify the PoKeys connection and inputs with the PoKeys configuration application under Support guidance, then check Mach software panel configuration. The startup sequence and normal software-controlled panel functions have different owners.
- PoKeys cannot be found: Check panel power and the physical connection first. See PoKeys Lost Connection for the separate recovery procedure. Clearing settings or recovering firmware can erase configuration; do not use those actions as an initial troubleshooting step.
Information to give MachMotion Support
- Control model, serial number, and panel part number/revision.
- Whether the PC powers on, and whether the beeper, power light, and marquee run once.
- Whether the button starts the PC before Mach software opens, resets Mach software while it runs, and can shut down the PC after software closes.
- Whether the problem began after a motherboard, BIOS, PoKeys, PoBlocks, or Mach software change.
- A short video showing the startup sequence and button behavior, if safe to capture.
For general control features, see the 2000 Series Controller guide. For panel connection recovery, see PoKeys Lost Connection.