TB6560 4 Axis smoked after power on (3.5+ years old) + pics

[Graphicman]

Hello guys

I had my tb6560 4 axis board for more than 3.5 years now and it was working flawlessly
never gets hot nor the motors, never had any problems with the board, not even missed steps
I am not a hard worker on it but I use it often

yesterday was working fine, today just powered up and it did not operate and I started to smell the smoke

I know and heard about the so many problems of this board but this board worked flawlessly all the past years
I did not change anything since last time it was working
I operated and it worked, jogged the machine a little bit then I clicked the soft stop from mach3 (` key)
then it seems that I accidentally clicked it again so i clicked it again to put the machine on sleep as it is nosy and I was fixing a job on the table

then when I tried to operate again it did not operate and I started to smell the smoke, turned it off and took those photos

any explanation for this?
can it be fixed?
I cant spot any damage other than those 3 spots
a blown small component (dont know its name) model E388
and these cut off wires

any help would be greatly appreciated








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[Jim Dawson]

The E388 is an opto isolator for the encoder input, and the damage looks like it was hit with high voltage. Based on the damage to the board, I would be taking a hard look at the cable and the motor for that axis. It looks like the motor power voltage was crossed to something, a dead short somewhere.

[Graphicman]

The E388 is an opto isolator for the encoder input, and the damage looks like it was hit with high voltage. Based on the damage to the board, I would be taking a hard look at the cable and the motor for that axis. It looks like the motor power voltage was crossed to something, a dead short somewhere.

Thank you Jim for your respond
the machine have been working and joging just few seconds before it did not want to work again and smoked, nothing have changed since ever, the electronic enclosure is well ventilated and well kept away
the only thing is that frequent soft stop (by mach3) i dont recall I ever made that before, but could be that a reason to blow a board?!!! really weird

culd it be fixed? as I can see the main axis chips are ok

[Jim Dawson]

I don't think the soft stop caused the problem, unless there was some kind of a voltage spike. I'm pretty sure there is more damage than you can see by looking at the board. It looks like the X? axis driver chip shorted out internally. It also looks like the motor voltage was crossed with the 5 volt. Why the high voltage crossed to the /B input is still to be determined. I'm pretty sure there is a short in the cable or motor.

Can the board be fixed? Maybe, if you can find the replacement parts and are good with a soldering iron. I can't see any numbers on the driver chips, but at least one will have to be replaced.

EDIT: It looks like the E388 is a resistor, not an opto-isolator.

[Graphicman]

I can totally understand it if the machine was running a long hard job and did that, but the way it did that is really weird!
mabe the numbers you are looking for are under the paste that i did not remove so far
however from what you have said, yes it is the X axis, would the board work if I d/c the x axis?
it seem like the damage prevent the board from working at all, i did not try to operate it again after it smoked
dont know if the fan will even work, do u want me to try that? mabe that will tell us anything at all?

[Jim Dawson]

Again, it looks like the motor high voltage was crossed with the 5 volt. I'm pretty sure there is a lot of damage that you can not see. You probably won't hurt anything by connecting the X axis to the D axis. BUT, I still think there is a short in the cable to the X axis motor, or in the motor itself.

EDIT: I did a bit more research. the TB6560 seems to be the part number on the driver chips. And the /B is an output, not an input. But there is still a short somewhere.

[Graphicman]

I made the connections myself it is really hard to imagine any crossed wired in my setup because it was made with great care
about the high voltage spike, I think the board has a self protection for that and other protections (amps and over heating)
I meant can I test the board without connecting that axis at all or any axis just to test a power on?

[Jim Dawson]

I'm not saying that the wires were crossed by you, I'm saying that they got hot and shorted out in the cable or motor.

You could disconnect the axes and power it up and see what happens. Maybe it will work.

[Graphicman]

just did and it worked, the fan worked, so this should say something

important note for you
once it smoked I checked the board and there was ABSOLUTELY NO heat or warmness whatsoever in any of the heatsink nor ANY component apart from the smoked areas
the machine was completely cold when that happened

so what now?
shall I try to connect just one ok axis?
I really dont want to fire my parallel port too
what do you think?

Edit
so weird the board is running the z axis that I have only connected, I think I might be lucky running at least the other 3 axis!!, wow what a relief

[Jim Dawson]

Maybe try one axis. The parallel port SHOULD be optically isolated so may be OK.

I would just buy a new board. https://www.ebay.com/itm/TB6560-4-Ax...sAAOxySoJTV2om

[Graphicman]

I would buy the 6660 instead
but with that being said, what do u think has happened to the board?
the main chips seem really ok, and i am about to test the other 2 axis left for me

[Jim Dawson]

What happened? I don't know. There is a small possibility that two of the output transistors turned on at the same time, not likely, but a voltage spike might cause that. I would be looking for a short in the motor or cable.

I would still buy the new board.

[Graphicman]

ok latest update
the board now is working on the 3 other axis, only x does not work so I switched inputs for X and A axis, did the same for ports in mach, and now it is working like normal but with no A axis (rotary)
still mysterious what happen to that board after more than 3.5 years at a time of cold run with no load at all!

[Jim Dawson]

Happy to hear it's working !

[Graphicman]

yeah man thanks a lot though
just finished a somehow hard project on it, we will see how it goes

[Toinvd]

The blown part E388 is ( was ) a protection diode.
This could be any fast ( shotkey ) diode that can handle the current and voltage In this case about 3A 40V
Any spike, or even moving a motor by hand can cause this. Although protection worked for several years, now it missed and fast electronics can also go away fast.

[Graphicman]

Toinvd Thank you very much for your input
I am not by any means a specialist in electronics departments

the next day the same thing happens to 2 other axis, leaving me with only the y axis which is hocked to 2 dual motors using double the amps settings i am using on the other axis (50%)
but this time there was no blown parts nor any smell!
does that tell you anything at all?
what if I changed these diodes would it work?
should I switch to unregulated power supply to avoid this issue in the future?
I was using 36v (100% of the driver support)
is the E388 diode is a protection for the motors or the driver board?
the problems happend ONLY when I pressed the soft reset on mach3 in the 2 times
hope you can answer my questions

thanks in advance

[Toinvd]

There could be something wrong with grounding ?? and running on 36V is on the limit for these however, it has been working fine for years.
Can you check your power supply if that is going a bit higher or other bad in another way, it might also blow the driver.
Replacing the diodes won't fix the problem, most probably also these drivers died.

[Graphicman]

checking the power supply was the first thing I did check specially when the same thing happened again the next day/run
it is perfectly fine, 36v dead on
not to mention that I am only using a fraction of its power (36V 11A)
my steppers settings are about 3.75A only (25% X 3, 50%Y Axis) -0.75A because I am disconnecting the 4th axis 99% of the time

it is really hard to imagine that the main chips died because the rotary axis was barely used and it failed once I used it as X instead of the failed one in the first time, it did a project and the next day/run it failed

the ironic thing is that the only working axis now is the Y which is set up on double the amps of the others!
it is really mysterious to me still and I really did not make any recent changes to the board
you think the diodes failed after the main chip failed?!
or even it was the cause of the diodes failure?
I have someone checked the diodes for me, he said he found only 4 working out of the whole line but they are not even beside each other (y xis)
there are some other diodes in the line that belongs to the power and the spindle relay that I have never ever used, why would it fail?!
btw does the main chip draw power if its axis is not connected to a motor but configured in mach3?

[Toinvd]

These diodes ( 5 for each axis ) should prevent the voltage from going negative. 4 are for the wires to the motor, the 5th is on the power input for the driver chip. the 21ths diode is to protect the transistor that switches the relay
If only 4 are working, that means the others are "open" and won't do anything at all. Bad protection on the board.
I expect that the first problem did some more damage to the board ( parts on it ) which resulted in the fast subsequent dead of other driver chips.
As you can see in many articles on this forum, the TB6560 doesn't have a good reputation. It;s famous for problems. The chip itself isn't to bad, but it's sensitive to all around.
The higher current for the Y driver is hardly a reason for a higher failure chance. Most electronic parts die because of a ( very short ) over voltage or reverse voltage. They Flash through and it's finished.
The main chip will only draw a tiny bit of power when configured, but no motor connected. It will try to deliver the power until output voltage is at max, Nothing bad should happen as long as you don't connect anything when power is on.
If you can afford, have a look at separate drivers and a breakout board this will have much less chance that one failure will affect the other drivers.
The picture is the inside of my box, I use a CNC-USB MK2 card and 4 DQ542MA drivers running from a 36 Volt 9 A power supply stable for about 4 years This is connected to an old small PC not connected to the internet.
I take the files from my PC on a USB stick to this set.