Need Help!- Help with Mach3 and missing steps G540

[tristen0821]

I was using a tb6550 board from hubbard but it keep missing steps and some of my steppers would get hot some would stay cool all at 75% amp. So recieved a g540 for christmas and I thought my troubles were behind me. Though it is better I am still missing steps both in 2d and 2.5d. I even build a new cnc with better bearings and is very easy to turn each threaded bolt by hand.

I am Waisting my time and wood$$ I have spent several hrs and tuning motors and reading forums looking for answers. I have contacted Gecko but they just tell me slow down the machine but it still looses steps. More evident in x and y cnc project is history after waiting hour or so i have to start over just try again it happens at different times during cnc project. It pauses some times but I am not sure why and then it continues ok. others totals project

Here is my set up I have tried 2 different computers 1 a dell 2.4 with xp 2gigs ram and compaq 2.8 with 2 gigs of ram both desktops. My both in epp mode and mach 3 ver r1.83.027. i have loaded file for mach 3 from gecko. steppers 2amp 24v 6wire minbea motors wired full, tuned at vel 35, 6accl, step pulse 2 set to run reverse on my setup. 6.4amp 24v powsup When running it has some power takes alot of effort to stop threaded bolt from spinning. gecko tells me my setting are two high but i can take acc up to 90 setting wave a 45 degs. and then it starts loose right away by just jogging cnc. I put mach3 in sherline mode 35hz to see of it helps but still same problem.

I create my designs in corel draw and export to WMF import to lazycam to scale and produce g code. I have also used cambam and Freemill with mach3in and Mach3sherline all with same result. Every now and then i get lucky and the project is finished.. I should just be able to position wood and comback later to the finished job.

If anyone can please HELP ME WITH SOMETHING TO TRY THAT Could fix this problem. I DONT KNOW WHAT TO DO ANY MORE.. at times i just want to give up. I think something is just not set right and i am not realizing it.

Any help is greatly apprecated.

Thanks for reading this post hope you can help!

[Mogal]

Thats a very old version of Mach3. Current version is R3.042.40
If Gecko is telling you your settings are too high, I think I would listen.

What are the speeds your getting now?
What is the thread pitch of the rod your using?

Start at a slower speed, a speed you know your not losing steps...
Once comfortable with that speed, increace the speed 10% - repeat till you start loosing steps, then back off 10%

[tristen0821]

it has 13 threads per inch and seems to do fine at 40inpm. I sat one day and connected a wireless keyboad to it for 2hrs just joged it all around while wacthing tv. the motors never made the groaning missing step sound.

I did notice today after it messed up again. while i was trying to line it up again to pickup where it messed up. I was joging through the code looking at mach window to see where it would be on the drawing and what line code when i notice it paused for about 2 sec just scrolling through code. Just like when it was runing.. Something in my setting or pc (Xp) is causing this i think. though i have seen it do this and finish a project it is speratic and inconsitant when it occurs again its a gamble if the project is continuing to be completed correctly or scrap wood.

Thanks for your response I am greatful for any help!

Thank! again.

[tristen0821]

I thought of upgading mach3 but funds are low and i would hate to have same problem.

I thought maybe trying emc and using a drive i have laying around for new os.

[restless1]

that version of mach is so old and has so many bugs i would uninstall it install the new one and do something in under 500 lines of code and try that...
you can use the latest mach 3 without a license as long as its under 500 lines of code..
trust me that version of mach will cause you headaches...

[Mogal]

K, so aside from an old version of mach3, your running win xp.
Is the computer hooked up to the CNC machine dedicated to it?
Or is it used for everything you do? Is it bloated with lots of software?
Can you format the computer to have a fresh install?

With only 13 tpi rod, your speeds won't be too fast.
Do you lose steps at 25ipm?

[dgates80]

I am pretty sure that Artsoft will upgrade you to latest rev for no cost, they are pretty good about that -- they consider it part of routine ongoing support for their product. I would definately check out their web site, maybe give them a call. I think you'll be pleasently surprised!

Update: Driect from the Mach 3 web site:

In the past 4 years, Artsoft has freely updated all previous versions of Mach for its customers. This policy still remains today. Any current version of Mach will be free to update for the duration of its development.

A license is only required on the computer(s) actually running the machine(s). If a computer not connected to a machine is used to test code, please use Mach3 in Simulation mode - it will remove the 500 line limit. Simulation mode can be accessed by uninstalling (or not installing) the Parallel Port Driver.

[tristen0821]

It is a decitated computer but not a fresh install.. there may be some stuff runinng in back ground. And i will save my pennys to upgade mach 3. The setup was given to me I do not hold the lic. It works fine with in 500 lines past that it messes up around 1000 or so simulations run fine system counts. I cannot duplicate missed stepps in jog mode unless at 80 or 90 inpm.
I am selling signes and stuff made to get the funds for it if i dont spend it all on wood for project restart. I was not a cnc fan before but now i am Hooked.

I am useing all free software except mach using blender for 3d or 2.5d Promised myself i would not put more $$ unless it pays for itself minus my time of course.

Want to make a mill or plama cutter once i figure this out and get $$ from projects.


Thanksyou everyone I am far from a pro. But if there is a will there is way.

I will keep trying and hopfuly not crying.. by cleaning out pc and runing only software for cnc.

[Mogal]

Thats great about a donated machine, too bad about the licence.

I think I would make Mach3 my number one concern, and get that upgraded ASAP.

[Mariss Freimanis]

Make sure the step outputs are set to 'active high' in Mach3 'Ports and Pins'.
Make sure 'Step Pulse Width' is set to '2uS' in Mach3 'Motor Tuning'.

Mariss

[gmfoster]

You seem to have some misconceptions.

Mach 3 is free to try at all levels. However it is limited to 500 lines in the demo mode.

If you have an old version that runs over 500 lines and it was truly donated to you then the license file is on your computer and you can upgrade and only have to be sure the license file is where it belongs.

If the donator kept a copy of the license then you are no more legal running now than you would be after upgrading. All up grading is is downloading the new version.

And you may well be wanting to much speed with 13 tpi screws.... The mach site gives all kinds of info about getting XP to work well with mach, and I hope the computer isn't a notebook..

[zeeway]

You have to make absolutely sure that your computer doesn't have any background programs that pop up at odd times to tell you they need updates, etc.

There is also a strong possibility that your computer is not putting out a consistent pulse stream through the parallel port to the motors. I had a problem with random lost steps a year ago until I installed a Smooth Stepper board - problem solved.

There are always more opportunities to spend money with CNC...

Angie