System stopped working, will not home or jog.

[AnthonyOhio]

Centroid CNC11 with DC3IO and Ajax 29in/lb motors.
This is a newer system, only used about 30 days since install.

The system was working on thurday without any problems. I finished a part and performed a normal shut-down.

Saturday I turned on the machine and pressed cycle start to home the machine and received an error regarding the optical connection. I attempted to jog the machine in all axis and it failed showing 410 errors on x, y, & z, and one 411 error on Z.

I shut down the system, remove each fiber optic cable blew the connector out with air and reinstalled one at a time.
(when I received this drive it did not have plugs preventing dust/dirt from entering the fiber optic ports, and the base was bent. )

Rebooted the system. =same problem
(1) 05-14-2011 13:59:18 199 CNC Started
(1) 05-14-2011 13:59:18 Dual port base address = 0
(1) 05-14-2011 13:59:40 411 Z axis(3) full power without motion [homing attempt]
(1) 05-14-2011 13:59:45 406 Emergency stop detected
(1) 05-14-2011 13:59:47 410 Z axis(3) position error [jogging attempt, same result on all axis]

I tested the limit switches using the alt-i screen. =OK
Checked servo power supply voltage. =OK
I Turned off stall detection. =No movement of servo motor
Connected motor leads to servo power directy. =Motor works
The drive board displays #1 (as it should)
The MPU11 has the 3 solid and 1 flashing led (as they should be)
All machine voltages are normal.

Monday
I rebooted the system and I still have the same problem.

I believe that the drive board may be dead.

Any other ideas, I am out of things to check.

[cncsnw]

You wrote:

Saturday I turned on the machine and pressed cycle start to home the machine and received an error regarding the optical connection.

What error message was that?

Connected motor leads to servo power directy. =Motor works
The drive board displays #1 (as it should)
The MPU11 has the 3 solid and 1 flashing led (as they should be)
All machine voltages are normal.

Did you connect the motor leads, and measure DC voltage, directly on the VM+ and VM- terminals of the DC3IO? Or did you go back to the rectifier/capacitor assembly? If the latter, check voltage on the DC3IO terminals. It is possible that power is not getting through the E-stop contactor.

If you have good DC voltage at the VM+ and VM- terminals; the limit switches are all closed; and there have been no software or parameter changes; then it is likely that you have a hardware failure on the DC3IO unit.

You could, of course, make this happen by changing all the Kp, Ki and Kd values on the PID configuration screen to zeros; or by updating from early CNC11 v3.01 software to later CNC11 v3.03 software without setting Parameters 300-303; but that does not appear to be the case here.

[AnthonyOhio]

Thank you for the response.

The optical error I did not write down and it is not in the log.

I measured the voltage at the board.

I did not make any changes to the software, and checked my PID config just now =ok

I hate the thought of pulling that board out; but, I guess that is the only option left.

[AnthonyOhio]

The new DC3IOB arrived last night and I installed it this morning.

LED1 is showing a 0
DF & PLC OK leds are not lit

Error messages in CNC11 are:

301 Stopped
9099 Message Cleared
9022 PLC Communication In Fault (Fiber 3)
9030 Spindle Fault
9022 PLC Communication In Fault (Fiber 3)

All limit switches show as tripped regardless of jumper position.

MPU11 lights are lit correctly

I switched fibers 1 & 3 at the DC3IOB & MPU11 to tect for a faulty cable =same results

Ideas?

[AnthonyOhio]

It appears that the DC3IOB sent to me is in Legacy Mode.

According to the Manual:
"When operating in legacy mode....the
base axis / error number display (LED1)....will display 0 during normal legacy mode operation and
will flash an error code if errors are detected."

And:

"To change between MPU11 and CPU10 [Legacy] compatibility modes, the DC3IOB must be reprogrammed by Centroid."

LED1 is displaying a solid 0

[AnthonyOhio]

Can anyone confirm this?