Chris, Andy, and Dave,

I guess I didn’t give enough info. I built this controller in 2005 for my 
lathe. I used it on my lathe until a couple of years ago when I added another 
drive and switched this controller over to my PCBmill and X2 Mini mill. I built 
a new controller for my lathe using a Mesa 5i25/7i76 pair so I could control 
spindle speed. The picture shows the two blown out parts. This controller 
worked for 15 years before letting the smoke out. I agree Andy, that it is 
difficult for a fault to continue to generate steps but that is what happened. 
It is possible that there was a design flaw but it worked for 15 years.
 In the program where things went bad the X-axis should not have been moving 
but it was. I was cutting a bushing for a keyway broach. For quite awhile 
everything was going fine and then suddenly it began to cut into the X 
direction when it was traveling in the Y direction. Then I saw smoke coming out 
of the controller box.
Jon Elson suggested that I may have blown out the parallel port which seems 
likely to me now that I think about the way it is behaving now.

Alan




---------- Forwarded message ----------
From: Alan Condit <condit.a...@gmail.com <mailto:condit.a...@gmail.com>>
To: EMC-Users <Emc-users@lists.sourceforge.net 
<mailto:Emc-users@lists.sourceforge.net>>
Cc: 
Bcc: 
Date: Sun, 1 May 2022 09:49:43 -0500
Subject: [Emc-users] Blown BOB and ???
Hi Guys,

I was machining a part on my X2 Minimill. Suddenly it left the programmed track 
(spoiled the part) and didn’t respond to Estop. I powered the system off 
manually raised the Z axis and tried turning it on so I could home it, smoke 
started coming from the controller. So I powered everything down and started 
troubleshooting.
There were two chips on the CandCNC Mini-IO BOB that had let out the magic 
smoke. I had a spare BOB that I built using the Gecko G540 schematic. So I 
replaced the other BOB with it. The drives in the controller are Superior 
Electric SS2000MD4 drives. 

When I got everything put back together and checked the wiring everything 
looked good so I tried powering it up. When I tried homing it the traces move 
in AXIS but there is no movement on the machine. The motors hold position so 
the output of the drives is active. Is it likely that I blew out the inputs on 
the drives?

Thanks,
Alan




---------- Forwarded message ----------
From: Chris Albertson <albertson.ch...@gmail.com 
<mailto:albertson.ch...@gmail.com>>
To: "Enhanced Machine Controller (EMC)" <emc-users@lists.sourceforge.net 
<mailto:emc-users@lists.sourceforge.net>>
Cc: 
Bcc: 
Date: Sun, 1 May 2022 08:59:53 -0700
Subject: Re: [Emc-users] Blown BOB and ???
There is a good chance there was a wiring error in you original setup.  The
fact the E-stop did not work tells me there was a design error.  E-Stop
should never fail, or rather if it does fail, the machine stops.  If the
inputs on the drivers are blown, that says the same thing.  Smaething was
wrong as that should never happen.

Diagnosing a system that has a design fault is really hard because our
brain tends to think of how a correct machine would function or how the
machine we THOUGHT we built should function.

The best plan is to ignore LCNC the BOB and all for now and see if you can
drive the motor drivers with a simple signal generator and no computer.
 If this does not work, you need to replace or repair the drivers before
you think about reconnecting a computer.   If you need to buy some test
equipment, now is the time.    At least a cheap square wave signal
generator and a cheap $12 logic analyzer t go with your multimeter.

Finally, you should draw a schematic of how you propose to connect the
computer and post it here for others to review.   They will check if
nothing else the e-stop design to see that it is failsafe and also check
that you have the power and computer parts properly isolated.   It seems
this may not have been the case in the past, and you don't want to simply
put it back the way it was.

First step is to verify the motors and drivers work independently of
computer control.



Chris Albertson
Redondo Beach, California

---------- Forwarded message ----------
From: andy pugh <bodge...@gmail.com <mailto:bodge...@gmail.com>>
To: "Enhanced Machine Controller (EMC)" <emc-users@lists.sourceforge.net 
<mailto:emc-users@lists.sourceforge.net>>
Cc: 
Bcc: 
Date: Sun, 1 May 2022 21:23:48 +0100
Subject: Re: [Emc-users] Blown BOB and ???
On Sun, 1 May 2022 at 15:53, Alan Condit <condit.a...@gmail.com 
<mailto:condit.a...@gmail.com>> wrote:

> I was machining a part on my X2 Minimill. Suddenly it left the programmed 
> track (spoiled the part)

How? It is almost impossible for a fault to cause extra steps. Does it
appear that one axis simply stopped moving?

-- 
atp
"A motorcycle is a bicycle with a pandemonium attachment and is
designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1912





---------- Forwarded message ----------
From: dave engvall <dengv...@charter.net <mailto:dengv...@charter.net>>
To: emc-users@lists.sourceforge.net <mailto:emc-users@lists.sourceforge.net>
Cc: 
Bcc: 
Date: Sun, 1 May 2022 13:57:54 -0700
Subject: Re: [Emc-users] Blown BOB and ???
Being used to servos the first thing I test is the estop. Saves damage 
to expensive mechanics.
Once I was testing a new interface. Running it from lower left to upper 
right. It was gaining about .1" every pass. ... after about 4 passes it 
took off for the upper corner at full speed: 400 ipm. My hand made it to 
the big red button ahead of the upper corner but knowing the axis estop 
limits were there and working gives piece of mind. Especially when the 
combined weight of the saddle and the table is 700 Kg.

Dave



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