Syil X4 - Comm Problem?

[irv]

I plan to contact Syil America, but knowing how long and how many tries it takes to get any response, I've come here first... probably better information here anyway.

So I just installed a 4th axis on my 4 month old X4 (regular not "plus") and everything seemed to work just fine. I was able to jog the 4th axis just fine.

After a little while of playing with it, I was reaching toward the back of the machine to move some cables and I accidentally pushed the E-stop button. Nothing was running at the time, and I rotated it, it clicked back into place and everything seemed normal. When I go to jog the machine... nothing happens.
None of the Axes work.
The machine turns on, and I can control the spindle from the machines front panel. I'm assuming this is some kind of communication problem from the PC to the machine, but since it happened right after the E-stop was pushed and also just a short while after the 4th axis was installed, I'm thinking it could be something else.

I restarted Mach 3, restarted the computer, unplugged the parallel cable several times, and I even re-installed Mach 3.

...still nothing

I don't see any obvious problems in the Electronics box.

Any ideas?

Thanks a lot for any help
-Irv

[Mac Tech]

Does Mach3 show the E-stop is active?

I believe others have had problems with the E-stop switch, but I think it was a pretty easy fix. Just tweaking the clearance for the switch or something.

[irv]

Does Mach3 show the E-stop is active?

No, its not active. The RESET button would be flashing right?
When I press the arrow keys to jog, the numbers change but the machine doesn't move.
Thanks

[irv]

Ok, I've let it sit for a couple days and it still will not do anything... so overheating is out I guess.

I have noticed that when I turn on the machine it doesn't click as loud as it used to. Like some kind of relay isn't working or something.

Any thoughts?
thanks
-Irv

[Mac Tech]

Fire everything up and press the E-stop on the front of the mill, the big red "Reset" button in Mach should start flashing.

- Press/Reset the E-stop on the mill a few times
- Go the the "Diagnostics" page in Mach3, you should see "LEDs" light up when you activate the E-stop and your limit switches.
- Open the back of the mill again and check EVERY connection you can find, just because it LOOKS like a good connection doesn't mean that it is
- Disconnect the 4th axis

[neilw20]

You may have the limit switch(es) configured foe E-Stop on limit or it is outside soft limits with soft limits turned on (probably not)
In the pin configuration, temporarily disable the E-Stop pin to regain control, or disconnect limit switch that is causing E-Stop.

[irv]

Fire everything up and press the E-stop on the front of the mill, the big red "Reset" button in Mach should start flashing.

- Press/Reset the E-stop on the mill a few times
- Go the the "Diagnostics" page in Mach3, you should see "LEDs" light up when you activate the E-stop and your limit switches.
- Open the back of the mill again and check EVERY connection you can find, just because it LOOKS like a good connection doesn't mean that it is
- Disconnect the 4th axis

When I hit the E-Stop, Mach 3 does nothing. Previously, if I turned the machine on/off while Mach3 was open, the RESET button would start flashing also... and it doesn't now. I already disconnected the 4th axis, and am in the process of checking each and every connection.
Thanks

You may have the limit switch(es) configured foe E-Stop on limit or it is outside soft limits with soft limits turned on (probably not)
In the pin configuration, temporarily disable the E-Stop pin to regain control, or disconnect limit switch that is causing E-Stop.

I'll try it, but I don't think my machine is even talking to the pc at all. I'm starting to think its a problem at the comm board. A loose connection wouldn't surprise me.
Thanks

[smallblock]

So I just installed a 4th axis on my 4 month old X4 (regular not "plus") and everything seemed to work just fine. I was able to jog the 4th axis just fine.

After a little while of playing with it, I was reaching toward the back of the machine to move some cables and I accidentally pushed the E-stop button. -Irv

I'm not familiar with these machines, but in diagnosing a problem, always go back to the last thing you did before the problem. Re-trace your steps in the installation of the 4th axis- did you connect new wires? Did you have to move other connections? When you moved the cables- did something pull loose? 99% of the time its a simple issue.

[Mac Tech]

Did you check the "Diagnostics" screen in Mach to see if "LEDs" lite up when you activated the E-stop and limit/home switches? This will check the basic connection between the computer and the mill.

[irv]

Okay, I'm happy to report that I found the problem. Well it wasn't exactly me.

I found that the Fuse on the comm board was burnt. I temporarily jumped it and the machine still didn't work.
I had my buddy (electrical guy) bring a meter and start checking components on the Comm board. He found a burnt diode right next to the fuse terminal.

I had a new diode soldered on last night and the machine is back up.

While I was checking all the connections on other boards I did notice the E-Stop connections were not making great contact, and I'm thinking that might have caused the power surge to the comm board, when I hit it.

Now its time to re-install the 4th axis... very carefully.

Thanks for all the help

[irv]

...gotta give credit
I called Syil America yesterday morning, and they called me back only a few hours later. Rod tried his best to help me over the phone, and it really sounded like he knew what he was talking about. His suggestions helped me to eventually find the problem.