So I just installed a 2’ extension on my my Pro 4x4 with servos and EX Controls. The machine was working well prior to tearing down part way for the extension install. I did disconnect all cables at the Acorn control box to relocate the bars etc.
I have everything installed and re-leveled and reconnected all of the cables to the Acorn box.
I did not install the rotary yet nor did I install the laser and pneumatic deployment box or cables.
I powered up the system and CNC12 using the same profile I was using previously (Avid 5.24). I immediately went into the Acorn wizard, changed the machine size configuration from 4x4 to 4x6, disabled the rotary by switching to “3 axis only”, and set the laser to none since I don’t have it hooked up. I then power cycled the acorn board and restarted CNC12 as directed.
When powering back up I’m getting a 407 Y+, X+, and Z+ limit errors on all axis at once. I can click the limit over switch on the top right and jog the machine but as soon as I stop all axis are tripped again. I checked all sensors and they are clear and I checked their function by tripping them with a screwdriver in proximity until they lit up. No issues there.
My machine coordinates are all negative with the extension so I’m assuming this may be what is driving the errors until I can get it homed. I clicked the limit over switch and then tried the home button. The Z axis started the homing cycle as usual, but it was moving down away from the limit switch and not up.
I’m not sure where to go from here. I’ve double checked the cables and ensured that they are in the right places on the control box. I have all cables properly labeled on each end so I know they went back into the same place they were removed from prior to the extension installation.
Does anyone have any ideas? I’m sure it is something stupid simple and likely something I’m overlooking, but I’m kind of stuck at the moment.
Sounds like your machine type is set wrong. Go back to your machine settings and make sure that not only do you have the correct machine and size selected but also that you have the correct motor type selected.
I just double checked. Machine is set to Pro CNC and motor type is set to servo.
I’m using the same profile I was using successfully prior to adding the extension. I just altered it to remove the rotary and laser and changed the machine length to 6’ from 4’.
I may try to set up a new profile and see if that does anything.
Yes, my machine is EX Control with all servo motors.
I just installed a new version of CNC12 downloaded from the Avid site. When I power the machine back up and start CNC12 everything looks normal. When I hit reset, the 407 errors on all 3 axis instantly appears even though everything on the machine is centered and not close to the sensors. When I click limit over, I get a 340 message on all 3 axis saying cleared, but after 5 seconds they go back to 407 and tripped.
if I move quick I can jog all axis with the keyboard or pendant after clicking limit over and everything moves in the right direction. But when I click limit over and then cycle start the homing procedure the Z axis starts moving down to to the spoilboard and not up to the sensor so I cancel the command and scratch my head.
Ok, this sounds like a problem with the sensors. With limit over NOT on what’s the state of your XYZA / Y2 sensors on the main screen? Are they white or amber? If either of them is amber when they’re not physically being tripped then you have a sensor problem.
The XYZA indicator on screen is amber when the limit over in not activated. The Y2 indicator on screen is white. It will turn amber when I put a wrench against the physical sensor to activate it but then clears when the wrench is removed.
As stated before, none of the lights on the physical sensors are illuminated while the XYZA indicator on the screen is active and the 407 errors are showing. I can however put a wrench against each sensor and the lights do illuminate.
I did not have the A sensor cable connected to the control box since I don’t yet have the rotary installed. I thought that may have been an issue so I connected the cable and a sensor making sure it functioned and was in a cleared state, but it did nothing to help the situation.
This means the the control thinks your XYZ or A sensor is triggered. That’s why Z is moving down when you home because it’s trying to clear that sensor.
Here’s what you need to do:
Unplug all of your sensor cables from the control box. (X, Y1 Y2, Z A, etc)
See if the light is still amber on your control screen. If it is you’ve got a software/control box problem.
If you don’t, plug one in at a time and watch to see when the on screen light goes amber. When it does, you know you have an issue with that particular sensor.
To add: If you start plugging in sensors and it goes amber on the screen, check the physical sensor it self to see if it’s also amber, indicating it’s triggered as well.
If it’s supposed to be triggered (like it’s near the end of travel on an axis) move it away and make sure it “un-triggers” like it’s supposed to.
If for some reason it doesn’t, you can unplug that sensor and continue troubleshooting the rest of them in that same way. It would be unlikely that you have multiple sensor problems, but this would at least let you test them all.
Quick question as I’m sitting in my office and not in my shop. I read last night while thinking of a troubleshooting solution that the sensors are NC. Wouldn’t unplugging the sensors create an open in the circuit thus triggering the indicator?
Hmm, so not everything you read on the internet is true. Interesting.
So I powered up the machine and one by one removed all of the sensor cables from the control box. X, Y2-, Y2+, Y1-, Z, and A. The XYZA indicator on the screen is still amber and has not cleared. I opened the box and jiggled the wires and connections on the acorn board around some and the indicator has not changed and didn’t even glitch a little when wiggling the wires. It was solid amber throughout the process. Per your advise it looks like we can rule out the sensors themselves. Any advise on next steps?
I did also restart CNC12 and the control panel with the cables disconnected to see if that might somehow reset something, and it did not.
I have never stepped outside of the Avid setup page. My machine is 100% factory Avid with no third party modifications. In the Acorn Wizard I have always stayed in the Avid tab and have never jumped into any advanced settings. I just set my machine size, orientation, and spindle using the Avid defaults.
I started with using the same profile I used prior to adding the 2’ in length. I just disabled the rotary, and the laser from the profile and adjusted the Y length to reflect the added 2’. this seems to have worked as the limits shown in move and jog show 49.XX by 72.XX with XX being a decimal i cant remember.
When that didn’t work I downloaded and installed a fresh profile yesterday afternoon and nothing changed. Sensor issue is still there.
If you have all of your sensors disconnected and you’re still seeing am amber light on the main screen (XYZA or Y2A) showing that one (or both) of those inputs are triggered you either have a hardware problem or a software problem.
Just so we’re on the same page that’s what I am talking about.
Again, one of those two lights shows amber and you have EVERY sensor wire disconnected, you’re running stock software (That is properly setup) then you have a hardware problem.
If your software is improperly setup, OR you have overridden any settings this can cause the controller to think that sensors are triggered when they are not. Big emphasis on that first point, make sure your software is setup properly (this video above will help you with that if you start it from the beginning)
I’m pretty certain that there are no overrides and the software is set up properly, but I will go down and reinstall a fresh profile and go step by step through the wizard to set up again and see what happens. I will leave all the sensor cables disconnected from the control box and see if I get a cleared XYZA indicator. I can confirm that the Y2A is not indicated as tripped (not amber) and it will turn amber when I hold a wrench close to it.
I downloaded and installed Router v5.24 u1 from the Avid website. I set it to the default profile in the Avid profile manager. When I launch the new profile (all sensor cables still disconnected) the XYZA indicator is amber. I went into the Utility Menu and imported my Acorn Router Pro license. Unlike what your video shows, after I import the license the XYZA indicator is still amber.
Once in the Acorn Wizard, in the General - Machine Set Up, I have Pro CNC selected and Motor Type is Servo. I set the width of the machine to 4’ and length to 6’ (Just upgraded with a 2’ extension). Spoil board dig in is set to off by default and it was left that way. My profile does not have any Soft Limit options.
Home and Park tab is set to Square Gantry. No park or move after home activated.
Cutting Tools tab is set to 4HP|3kw as I have the AV40S spindle and it is not an option on the list. Custom RPM is set to off by default and left that way. 5 minute spindle warm up was left as default.
Warnings and Defaults tab, all warnings checked. Low air set to Do Nothing. Run Time Graphics set to yes. Remember Last G-Code set to no. Enter Key Cycle Start set to yes.
Relay Behavior tab not used due to relay not connected at this time. Manual Trigger selected by default.
Operator Position is set to front.
In Accessories I have the Laser set to none as I don’t currently have it connected. Rotary i have set to 3-Axis Only since I do not currently have the rotary installed. Probe Installed is set to no. Touch Plate is left as default Avid CNC touch plate, Input 4, Input state when tripped set to closed. Wireless MPG is set to none. I have one and love it but to simplify trouble shooting I’m not including any accessories.
I then clicked “write settings to CNC control configuration. Finally I shut down the Acorn control box, exited the wizard (automatic) and restarted the profile.
Results - upon restarting the profile and XYZA indicator is amber, Y2A is clear. When I click reset the servo motors clunk and lock in place, but the XYZA indicator is still orange and Y2A is clear.
