New Machine Build- G540 Random Faults

[CamSec]

I`m having a hard time getting my new Taig mill with Gecko 540 from DeepGroove1 working reliably. I`ve been having a lot of problems with random faults. I thought I`d cured them yesterday by disabling the 2nd CPU and Hyperthreading, and have been able to make 3 quite complicated pieces (5 hours, 30 minutes, and an hour run time respectively), but now its faulting again about 20 minutes into a job. I`m using EMC, on a Xeon 2.8Ghz CPU (same as a Pentium IV but supports dual CPUs). Any ideas? What does the fault light actually indicate?

[cd_edwards]

Do you maybe have really thin serial cables going to your motors? I found that the 25ft and 20ft cables I had originally planned to use would cause random faults while moving. Motors were not attached to the table. As soon as I made up some proper cables with 18awg wire, my problem went away.

[CamSec]

The deepgroove1 supplied cables are 22 gauge. Maybe I`ll try taping down the cables so that the end going to the db9 connectors does not wiggle.

[CamSec]

Still faulted. It looks like it faulted at the exact same place in the program though?

[CamSec]

Meh, now it faults on a program that it was able to complete yesterday.

[CamSec]

I was taking the gecko unit out of the controller box to return to DeepGroove1, and the ground wire fell out without me unscrewing it. I re-mounted the gecko upside down so I could get to the terminals easily, secured all the wires, and it has run for about 7 hours without faulting so far..

[cncbill37]

I am having the same problem. Was the loose wire the problem?
I've checked wires and still no luck.

Ideas?

Many thanks

Bill

[CamSec]

A loose wire inside the cable was one of my problems, I also found a loose wire inside the controller box, where the wires screw into the gecko. If you pull on them they shouldn't fall out. I then proceeded to have lots more problems that were eventually solved by pointing a fan at the back of the Gecko. Hope this helps!