random estop

[erase42]

Hi,
I am using a second gen controller board and the latest version of the software. It is connected to a computer that had no problems running the original board. I have a problem with the system dropping into Estop at random times. I dont think that its the files in any way, they were made with deskcnc and ran fine before, also the stop will happen at different times each time I run the same file. It happens with any file I run, whether 20 seconds or 2 hours.
I have ruled out bouncing switches or wiring faults since there are no home or limit switches and no connections made to the board other than the sep/dir, power, and a jumper between Estop and ground as I believe the instructions call for if you dont have a button in use.
The software is version 2.0.1.79. Any help or further questions would be appreciated. The controller is running a foam cutter and every time it Estops it ruins at least one piece, at $3 to $20 dollars a piece its starting to get expensive and very frustrating.

Thanks
Ed

[erase42]

Hi again,
No one has a clue or had any experience with this? Is it possible its a faulty board? Has anyone ever had a new board be defective? Do any of you techies know of any other conditions that would cause an Estop. Does it have to be called for by the board connections or could software be sending a stop signal at the wrong time, and if so how could I log this. Ive been over every connection I can think of that would affect the problem.
Its starting to get frustrating, im mostly just throwing money away at this point now. I have thrown away a couple hundred dollars worth of damaged parts already plus Im running with a full handicap on production since it wont run long enough to produce anything while im gone, or after hours like I used to be able to do. It did run a 2 hour file yesterday which really surprised me.

Was this system not sold to be used commercially, I keep feeling that support people overlook my posts and emails because I am not a hobbiest using this. Im not asking for anymore than info or advice. Am i violating terms somewhere? If support needs any more information on the setup please let me know.

[imserv]

Have you contacted support@deskam.com ?

[erase42]

yes i have, but not concerning this problem, i wrote a very precise description of another "oddity" not bug, in the software that really messes things up. someone did reply quickly and i greatly appreciate that, but the reply was basically "yes if your axis is linear then set the software to linear" And the question was sort of, WHY does everything go wrong WHEN i set it to linear as is proper. I reposed the question with even more detail and havent heard anything in two weeks i guess. I figured id wait on this till i get an answer to that one. If you are experienced with deskcnc perhaps i can forward you that email? Ive been using it a long time, but this is new to me.
thanks,

Ed

[erase42]

update, Carl did write back, seems the original email was forwarded to the wrong dept since my subject line mentioned foam cutting. the bug causing one problem has been fixed. still no word on the random stops. they are happening less often, none in fact yesterday at all. Ive changed nothing, but the weather is a tad cooler. Im wondering if something on the board is heating and opening a circuit.

[imserv]

Is the board mounted in an airtight chamber with some hot stepper drivers, power suppply, or other components? Normally we recommend some airflow when installing the board in an enclosure with other compopnents.

A little fan action could be all you need to solve the problem.

Fred Smith - IMService

[ViperTX]

Well it could be that you're also getting some noise glitch on that line....since it happens pretty randomly.....can you go back to the 1st gen controller?

Just reread your message....you don't have an ESOP, but have it jumpered to ground.....well loose jumper or an intermittent ground could be the problem.

[erase42]

Hi Fred,
no its got plenty of air and a fan, sometimes it will stop during the first 5 inches of the first cut of the day when all is dead cold.

Viper TX,
no 1st gen board is dead and unreplaceable i guess, Ive checked that actual ground jumper a million times, its a factory plug and the internals of the plug ohm out at zero even if i wiggle or pull it, and the other end is secure under the screw terminal. Is it possible that the second gen board is more sensative to noise from some source that the 1st gen wasnt? Id hope the new board would be an improvement in that dept, but one never knows.
I guess if other people arent having the problem then its probaby something other than noise. I wish i was aware of some way to troubleshoot futher like disabling the estop command from the software and see if it still happens. but unless someone has an idea....

[ViperTX]

Okay, I just checked their website....they use an ESTOP that is a normally closed switch......so, what you are getting is probably not noise related as that signal has to open up....I would look at a faulty jumper.....make your own....look at the bottom of the board see if you see a bad solder joint or a loose pad.....also trace back.....they most likely have a resistor that is tied to that pin and VCC (pullup configuration if used it could be a bad solder joint or a cracked resistor...).....it would guarantee that an open switch would be properly sensed.....I'm just guessing since I don't have a schematic.....

[erase42]

thanks, ill redesign that jumper just for grins, as far as bad solder joint, its hard to tell. the board is made up of those tiny surface mount components. I am starting to think that it is something faulty on the board itself though. As i mentioned Ive noticed a reduction in stops recently, in fact i dont recall any today or yesterday. the only thing i can think of that is different other than slightly cooler weather, is that I have left the controller on all day and night for the last couple days. The more i think about it the more im convinced that something on that board has a cold solder joint thats doing something odd as it changes temp.

[drk]

I too have been using the deskcnc controllers for some time now and have had similar trouble with the software when using the estop terminal. In my machines, instead of going into an e-stop mode, the machine would start moving irratically.

I finally disconnected the estop and disabled to pin from the settings and have wired all the limit switches to power a solid state relay which then powers up the controller. Ideally, these switches are never hit, but if they are, the controller simply goes off and I can set things right then.

Dev

[erase42]

Hi DRK I have the estop disabled in the software as part of a test that the service dept wanted me to try. And it still stops from time to time. I dont have any other connections to worry about. But I think its been decided that the board has a fault in it and the new one should be here tomorrow. I hope that fixes it because if it doesnt then there is something here that is extremely intermitent and its going to be a project to locate as ive already been thru everything half a dozen times. Ill update when i get the new board hooked up. Thanks again to Carl thats shipping me a new board.