Intermittent Drive Fault Error from what looks like z drop (EX Controller)

1

Hello,

I have an intermittent issue with my CNC similar to another thread I found here. Intermittent "Drive Fault" error – job stops randomly (EX Controller) . It also seem similar to the thread titled “Machine Movement” by bhlwoodworks (sorry, the forum only lets me put in 2 links).

Backstory on the machine: I bought this machine used and did an EX upgrade to it immediately when I got it home. I went through the upgrade instructions twice. I have changed the settings in the VFD programming for the EX controller per that instruction set. I downloaded the CNC12 software from the avid site in the month, so I believe I should be up to date there.

What is happening, is an intermittent issue where when I go to run a job the z axis drops suddenly about 0.050” - 0.080” and produces a drive fault. I believe I have seen it trigger both a drive fault and the general job fault 327. This happens about every day that I try to run the machine now. I can run some jobs fine and then when these drive faults start, there is nothing I have figured out to remedy it, other than shut everything off walk away for a while and return to it a few hours later. (But turning everything off for a few minutes and rebooting hasn’t seemed to help).

The fault can be produced without even cutting material. Attached (hopefully) is a video of the fault occurring. Here I am trying to run a simple linear pass in the y-direction that I programmed from intercon. It does not matter if the machine is plunging at plunge feed rate in Z (very slow thinking it was too fast of movement), or feeding in the y-direction (it is not consistent where the spindle makes it too in the movement), but regardless it seems to consistently drop the Z axis when it produces the fault. This probably happened about 10 times today while I was trying to get the program to run, but ironically the first time I pulled out my phone to take a video of it, the drive fault didn’t occur. So it is intermittent.

https://youtube.com/shorts/6EAOMZEDrWU?feature=share

Prior to this video this morning, I ran the same linear pass program in the X direction and air cut in a couple different places on the table in the X direction and tested it multiple times at various Z heights to make sure I was comfortable before cutting down on the spoilboard.

I have tried wiggling wires on the Z-axis servos while the machine is in its movement from the home position to the cutting position in the program and cannot seem to produce the drive fault that way. I have also tried removing the vacuum hose entirely with no results either.

While I am pretty new to having my own CNC, I do have some experience on others equipment. I am not ruling out user error in the slightest, but I have done quite a bit of checking and rechecking and have a gut feeling it is a similar issue to the threads mentioned above. I have also contacted support, but figured I would start a thread here seeing Eric is so responsive. I also would like to get this figured out quickly as I have a job to run this week for a rush Christmas order.

2

Glad you made a ticket with support. You should stick with their lead.

I am just guessing here, but I wonder if the issue here is a sticky Z axis… It wouldn’t hurt to lube it up per our maintenance instructions and see if that cures the issue. If a motor exerts too much torque and can’t keep up it will send a fault signal, which is what might be happening here…

3

Thank you. I will lube the z axis (all axes) and test / report back. That is a great suggestion I overlooked.

One other thing I should note, and I am not sure if it matters, but my upgrade kit was dispatched early in the release last year at the beginning of November. My question is, did everyone else who reported problems and it seems like there were some servo settings/tuning that you and support helped with, was that related to early servos sent out? Are the servo settings in the servo logic boards themselves, or does that all get updated with current versions of cnc12?

Thanks for the help. And apologies for the long original post.

4

We did have some servo tune updates.

You can get a new one by contacting us:

Try lubing it first.

5

What is the proper way to contact support? I sent an email from the support@avid email I was using when I placed my order. Should I be going through the contact us page on the website instead? Or it doesn’t matter? Just want to make sure it gets into the system que properly.

Looking at that error page, I definitely ordered and received my servos before the 11/26 date listed. I will still try lube first.

6

Your ticket is in there. They are triaged every day so you’ll be hearing from someone soon

7

Thank you for the help Eric. I have lubed my z axis and can still produce the 9031 drive fault. It is intermittent still as I started out making 2 air cuts and 1 actual cut in a row. I needed to step over and run again and now am getting about every other pass with the drive fault. This is both in air cuts up above the work or zeroed down on the spoil board.