Need Help - Programs working for Years they all get error codes

[richlandrick]

Boy I sure I hope somebody out there ca n help me.

I have been using Mach 3 for several years. My programs are all proven and have been working for years as well.

Yesterday the machine waited an extra move before invoking radius compensation, cutting the corner of a piece. Today, it did the same on four pieces.

Mechanical causes are absolutely ruled out.

Now I get an error message for these programs that haven't changed in over a year. The error is "radius to end of arc differs from radius to start line 12. Here's the rogram part of the program invoking the error

N5 (File Name = DL650 fork brace 4 shapes on Sunday, March 08, 2009)
N10 (Default Mill Post)
N15 G91.1
N20 G0 Z1.5000
N25 M3



(Start Upper Left Outside)
G0 X12.3 Y5.9
G41 D4
F26 G1 X11.9140 Y5.6
G0 Z-0.125

N325 G1 X11.9140 Y5.5000
N330 Y5.0500
N335 G2 X11.6640 Y4.8000 I-0.2500 J-0.0000

[ger21]

What diameter is tool #4?

It doesn't look like your showing us Line 12, so I can't tell you if there's a problem there.

The only thing I can tell you, without seeing more of the code is to uninstall, then reinstall Mach3.

[richlandrick]

I have loadede a more recent version of Mach with no change. The program is cut and pasted. Mach highlights line N335 when it it gives the error. I think line 12 is just the twelth line from the top including blank lines.

[richlandrick]

OK. When I replace G91.1 with G90G80G49 teh programs work again. Why would G91.1 suddenly have issues?

[ger21]

G91.1 is incremental IJ. Are the programs using absolute IJ?

[richlandrick]

I don't actually know. I have been using lazyCAM and inserting G42 and G41 as appropriate. Can someone poitn me to explination of the difference so I can see which one was generated.

Still, the programs workerd for a very long time, then didn't.

[richlandrick]

Is it possible that the setting affecting when two lines are near each other are considered continuous have changed? Where could I find that setting?

[ger21]

There is no setting for that. Or do you mean in LazyCAM?

[richlandrick]

Thanks,

I'm pretty sure the program is written in incremental mode. Now here is a twist. I have a hobbyCNC profile in Mach. Teh program with G91.1 code loads fine with the hobby cnc profile. In the profile for my break out board I get the error metnioned int he first posting.

I wouldn't have thought the profile would have made a difference. Dioes that help anybody understand what might have changed?

I really apreciat ethis. I'm abotu to leave town and need to get this machine working again before I go.

[Kiwi]

Please show line N340 or next block.

[richlandrick]

I didn't change a thing in the program and now verything is back to normal. Very wierd. I am taking a day off from my regulaer job to make sure that it is actually "fixed" so that my son can run things while I'm, gone. Fixed doesn't seem liek the right word though since I don't know what chaged or brake.

Very wierd.