Mach3 issue (cnc problem)- unwanted pauses in programs at random times, including occasional resets. During the middle of a program, the x,y, & z axis will stop and the green "RUN" button will go out and the yellow "PAUSE" button will illumina
te on the MACH3 screen. Sometimes the pauses occur with NO BUTTONS being illuminated. No errors that I can see, sometimes a yellow bar will appear at the bottom portion of the code lines briefly when it pauses.
I have had problems with unwanted pauses for some time. I used to constantly lose power on the z axis, I traded gecko drives with the x and instead of my z going out my x was going out... It literally would be a lump on a log and just sit there, I could jog up and down and no movement would occur, BUT the mach3 screen showed the movements so it looks like it was sending the signal, just not receiving it. This problem has only happened twice with the new G320X gecko drives (instead of all the time prior to replacing the faulty drive), both times it was on the Y axis and I checked the motor tuning config which showed that they had been tweaked with. I restored factory settings to the velocity and acceleration on all 3 axis. Factory speeds state up to 800 inches per minute, I currently have these settings for both x and y axes; velocity: 400, accerlation: 30,G's: 0.077705 with step and dir pulse both at 0. The z axis velocity is 32.658 and Acceleration: 4.54125 and G's: 0.011762, again step and dir pulse both set at 0.
COMPUTER: 420@ 1.60GHz Celeron D, 2GB DDR2 RAM. 160GB HD, Sony CD-RW, Windows HOME SP2 OS.
CNC: Dyna DLI4848RSR-DA 4'x4' work area (68"x68" Table size) CNC with MCG ID33004 Servos (14.10 lbs/in. 90VDC 7.8amps) equiped with US Digital Optical Encoders E5D-500-250-EG (E5 series), Colombo 3HP Spindle with Delta VFD-B.
CONTROLS: DY400-K2Y (I believe made by CandCNC.com ) with external DL200 backlit LCD. Installed inside the control box are three new G320X servo Geckodrives (previously G320- I had one of the gecko drives fail and upgraded all 3).
AFTER ADJUSTING CONFIG - MOTOR TUNING: I ran a wood coaster program and the first time I ran it it paused at line N7710. I clicked on RUN and it resumed, then around N16400 it paused again and RESET TO THE BEGINNING. I am not sure EXACTLY where this occurred as it was running through the program and all of the sudden paused and the lines of code skipped back to the beginning, as if the program had ended... The 2nd time running through the entire program (which has 3 parts) ran with only 4 pauses, and no resets. The 2nd time it pauses at line N8840, N9260, N32590, and N37550. There were no errors shown, just pauses where the pause button would illuminate (half of the time). Here is a link to the numeric code as an example; www.LeviManselle.com/coffee/coasterhappyrock2b.txt
Below are photos of the cnc for reference;
After opening my profile, here is the screen I see... This is the program page. I have another 3 pages I can select; MDI Settings, ToolPath, and Diagnostics.
Above is the control box panel, it shows the model as DY400K2Y. I believe this was made by CandCNC,
Inside the Control box, Geckodrives on RIGHT. There is a gray cardboard shield covering the bottom, where the capacitors are.
Better closeup of main board... E-Stop can be see on right side (photo was taken at a 90 degree angle)
Here the cardboard cover is removed, to show power in, relay switches, power out (outlets are not used).
Another close up- mini bus fuses can be seen here... (5A)
The circuit board has DY400 shown, anyone know who made this PCB?!?
Outside of control box - from computer to box to cnc.
Limit switches, which seem not to work... Possibly disabled right now?
Colombo Spindle - 3HP. Delta VFD-B not shown.
MCG 14.1 lb. Servos - ID33004 (I think around 225 oz.) 90VDC, 7.8A
US Digital Optical Encoders, I believe these spec out at 500 lines, E5D-500-250-EG (E5 series).
Here is the program running, no errors so far....
OOPS! Here is the first "pause" which took place on line N7710. This is really line number 771, all lines are labled in 10's - and this particular code is a basic G1 line. There were a series of other similar small lines that took place prior, no G00 rapids, or anything of that nature... I have no clue why the program paused, it does that randomly... I hit run, and it ran for a while after that, then....
Out of nowhere the program reset itself. The spindle stayed on, the program "paused" again despite no pauses or m02 or m99 or whatever... Pretty bizarre, you can see the green highlighted tool path of how far the program had gone since the pause in the last photo... Again - NO CLUE why this has happened. I restarted the program and ran it from the beginning again.
Usually when a program is running I leave it on 1 screen, I do not do anything else on the computer either... During the 2nd time through, I switched to the diagnostics screen to see if there were any errors or signs of problems... I noticed one red box.
Do you see it? Output 5 is red!
Here the program is running, so far so good....
I spoke too soon... Another pause, this is the 1st time it paused (2nd time running same program though) at line N8840.
I hit run, a little while later another pause... at line N9260...
Hit run, another pause a while later at line N32590!
Diagnostics doesn't show anything out of the norm... other than above mentioned....
After another pause at N37550, the rest of the program runs without issues.
I switched screens a few times to see if it would make a difference, the program finished after "only" 4 pauses... The 1st program run didn't complete (1 pause and 1 reset) but the 2nd time through there were 4 pauses and no resets. The 3 different passes with 2 tools only had above mentioned problems, unsure why this random pausing continues to be a problem. Any ideas?!?
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